(word)-模具专业毕业设计外文翻译--基于注塑模具钢研磨和抛光工序的自动化表面处理-模具设计

译文标题基于注塑模具钢研磨和抛光工序的自动化表面处理原文标题AUTOMATEDSURFACEFINISHINGOFPLASTICINJECTIONMOLDSTEELWITHSPHERICALGRINDINGANDBALLBURNISHINGPROCESSES作者FANGJUNGSHIOUCHAOCHANGACHENWENTULI译名晁常温途利国籍美国原文出处SHIOUFJ,CHENCH2003DETERMINATIONOFOPTIMALBALLBURNISHINGPARAMETERSFORPLASTICINJECTIONMOLDINGSTEELINTJADVMANUFTECHNOL基于注塑模具钢研磨和抛光工序的自动化表面处理摘要本文研究了注塑模具钢自动研磨与球面抛光加工工序的可能性，这种注塑模具钢PDS5的塑性曲面是在数控加工中心完成的。这项研究已经完成了磨削刀架的设计与制造。最佳表面研磨参数是在钢铁PDS5的加工中心测定的。对于PDS5注塑模具钢的最佳球面研磨参数是以下一系列的组合研磨材料的磨料为粉红氧化铝，进给量500毫米/分钟，磨削深度20微米，磨削转速为18000RPM。用优化的参数进行表面研磨，表面粗糙度RA值可由大约160微米改善至035微米。用球抛光工艺和参数优化抛光，可以进一步改善表面粗糙度RA值从0343微米至006微米左右。在模具内部曲面的测试部分，用最佳参数的表面研磨、抛光，曲面表面粗糙度就可以提高约215微米到0007微米。关键词自动化表面处理抛光磨削加工表面粗糙度田口方法一、引言塑胶工程材料由于其重要特点,如耐化学腐蚀性、低密度、易于制造,并已日渐取代金属部件在工业中广泛应用。注塑成型对于塑料制品是一个重要工艺。注塑模具的表面质量是设计的本质要求,因为它直接影响了塑胶产品的外观和性能。加工工艺如球面研磨、抛光常用于改善表面光洁度。研磨工具轮子的安装已广泛用于传统模具的制造产业。自动化表面研磨加工工具的几何模型将介绍。自动化表面处理的球磨研磨工具将得到示范和开发。磨削速度,磨削深度，进给速率和砂轮尺寸、研磨材料特性（如磨料粒度大小）是球形研磨工艺中主要的参数，如图1（球面研磨过程示意图）所示。注塑模具钢的球面研磨最优化参数目前尚未在文献得到确切的依据。图1球面研磨过程示意图近年来，已经进行了一些研究，确定了球面抛光工艺的最优参数图2（球面抛光过程示意图）。比如，人们发现,用碳化钨球滚压的方法可以使工件表面的塑性变形减少,从而改善表面粗糙度、表面硬度、抗疲劳强度。抛光的工艺的过程是由加工中心和车床共同完成的。对表面粗糙度有重大影响的抛光工艺主要参数，主要是球或滚子材料，抛光力，进给速率,抛光速度,润滑、抛光率及其他因素等。注塑模具钢PDS5的表面抛光的参数优化，分别结合了油脂润滑剂，碳化钨球,抛光速度200毫米/分钟,抛光力300牛，40微米的进给量。采用最佳参数进行表面研磨和球面抛光的深度为25微米。通过抛光工艺，表面粗糙度可以改善大致为40至90。步距研磨高度球磨研磨进给速度工作台进给研磨球工作台研磨深度研磨表面图2球面抛光过程示意图此项目研究的目的是，发展注塑模具钢的球形研磨和球面抛光工序，这种注塑模具钢的曲面实在加工中心完成的。表面光洁度的球研磨与球抛光的自动化流程工序，如图3所示。我们开始自行设计和制造的球面研磨工具及加工中心的对刀装置。利用田口正交法，确定了表面球研磨最佳参数。选择为田口L18型矩阵实验相应的四个因素和三个层次。用最佳参数进行表面球研磨则适用于一个曲面表面光洁度要求较高的注塑模具。为了改善表面粗糙,利用最佳球面抛光工艺参数，再进行对表层打磨。PDS试样的设计与制造选择最佳矩阵实验因子确定最佳参数实施实验分析并确定最佳因子进行表面抛光应用最佳参数加工曲面测量试样的表面粗糙度球研磨和抛光装置的设计与制造图3自动球面研磨与抛光工序的流程图二、球研磨的设计和对准装置实施过程中可能出现的曲面的球研磨,研磨球的中心应和加工中心的Z轴相一致。球面研磨工具的安装及调整装置的设计，如图4（球面研磨工具及其调整装置）所示。电动磨床展开了两个具有可调支撑螺丝的刀架。磨床中心正好与具有辅助作用的圆锥槽线配合。拥有磨床的球接轨,当两个可调支撑螺丝被收紧时，其后的对准部件就可以拆除。研磨球中心坐标偏差约为5微米,这是衡量一个数控坐标测量机性能的重要标准。机床的机械振动力是被螺旋弹簧所吸收。球形研磨球和抛光工具的安装，如图5（A球面研磨工具的图片B球抛光工具的图片）所示。为使球面磨削加工和抛光加工的进行，主轴通过球锁机制而被锁定。图4球面研磨工具及其调整装置模柄弹簧工具可调支撑紧固螺钉磨球自动研磨磨球组件图5A球面研磨工具的图片B球抛光工具的图片三、矩阵实验的规划31田口正交表利用矩阵实验田口正交法，可以确定参数的有影响程度。为了配合上述球面研磨参数，该材料磨料的研磨球直径10毫米,进给速率，研磨深度,在次研究中电气磨床被假定为四个因素，指定为从A到D（见表1实验因素和水平）。三个层次的因素涵盖了不同的范围特征,并用了数字1、2、3标明。挑选三类磨料,即碳化硅,白色氧化铝,粉红氧化铝来研究这三个数值的大小取决于每个因素实验结果。选定L18型正交矩阵进行实验，进而研究四三级因素的球形研磨过程。表1实验因素和水平水平因素123A碳化硅白色氧化铝粉红氧化铝B50100200C研磨深度（M）205080D12000180002400032数据分析的界定工程设计问题,可以分为较小而好的类型,象征性最好类型,大而好类型，目标取向类型等。信噪比S/N的比值，常作为目标函数来优化产品或者工艺设计。被加工面的表面粗糙度值经过适当地组合磨削参数，应小于原来的未加工表面。因此,球面研磨过程属于工程问题中的小而好类型。这里的信噪比（S/N）,按下列公式定义10LOG平方等于质量特性1010LOG（1）NIY2这里，Y不同噪声条件下所观察的质量特性IN实验次数从每个L18型正交实验得到的信噪比（S/N）数据，经计算后，运用差异分析技术变异和歼比检验来测定每一个主要的因素。优化小而好类型的工程问题问题更是尽量使最大而定。各级选择的最大化将对最终的因素有重大影响。最优条件可视研磨球而待定。四、实验工作和结果这项研究使用的材料是PDS5工具钢相当于艾西塑胶模具，它常用于大型注塑模具产品在国内汽车零件领域和国内设备。该材料的硬度约HRC33HS46。具体好处之一是,由于其特殊的热处理前处理，模具可直接用于未经进一步加工工序而对这一材料进行加工。式样的设计和制造,应使它们可以安装在底盘，来测量相应的反力。PDS5试样的加工完毕后，装在大底盘上在三坐标加工中心进行了铣削，这种加工中心是由钢铁公司所生产中压型三号,配备了FANUC18M公司的数控控制器099型。用HOMMELWERKET4000设备来测量前机加工前表面的粗糙度,使其可达到16微米。图6试验显示了球面磨削加工工艺的设置。一个由RENISHAW公司生产的视频触摸触发探头，安装在加工中心上，来测量和确定和原始式样的协调。数控代码所需要的磨球路径由POWERMILL软件产。这些代码经过RS232串口界面，可以传送到装有控制器的数控加工中心上。图6加工中心数控机床电脑完成了L18型矩阵实验后，表2（PDS5试样光滑表层的粗糙度）总结了光滑表面的粗糙度RA值，计算了每一个L18型矩阵实验的信噪比（S/N）,从而用于方程（1）。通过表2提供的各个数值，可以得到四种不同程度因素的平均信噪比（S/N），在图7中已用图表显示。表2PDS5试样光滑表层的粗糙度实验序号ABCDMY12MY3S/NDBMEANY_111110350350359119035021222037036038863403703133304104404075970417421230606506438760640522310730770782380076062312045042039753004207313203403103298010323832130270250281147102679332103203203298970320101122035039040839003801112330410500436968044712131104003904278830403132113033034031971203271422210480500476312048315233205706105348680570163131059055054503005601732120360360358954035718332305705305352930543图7控制影响因素信噪比控制因素球面研磨工艺的目标，就是通过确定每一种因子的最佳优化程度值，来使试样光滑表层的表面粗糙度值达到最小。因为LOG是一个减函数，我们应当使信噪比（S/N）达到最大。因此，我们能够确定每一种因子的最优程度使得的值达到最大。因此基于这个点阵式实验的最优转速应该是18000RPM，如表3（优化组合球面研磨参数）所示。表3优化组合球面研磨参数因素水平白色氧化铝0MM/MIN20M18000RPM从田口矩阵实验获得的球面研磨优化参数，适用于曲面光滑的模具，从而改善表面的粗糙度。选择香水瓶为一个测试载体。对于被测物体的模具数控加工中心，由POWERMILL软件来模拟测试。经过精铣，通过使用从田口矩阵实验获得的球面研磨优化参数，模具表面进一步光滑。紧接着,使用打磨抛光的最佳参数，来对光滑曲面进行抛光工艺，进一步改善了被测物体的表面粗糙度。见图9。模具内部的表面粗糙度用HOMMELWERKET4000设备来测量。模具内部的表面粗糙度RA的平均值为215微米，光滑表面粗糙度RA的平均值为045微米，抛光表面粗糙度RA的平均值为007微米。被测物体的光滑表面的粗糙度改善了215045/215791，抛光表面的粗糙度改善了215007/215967。图8被测物体表面粗糙度五、结论在这项工作中,对注塑模具的曲面进行了自动球面研磨与球面抛光加工，并将其工艺最佳参数成功地运用到加工中心上。设计和制造了球面研磨装置及其对准组件。通过实施田口L18型矩阵进行实验，确定了球面研磨的最佳参数。对于PDS5注塑模具钢的最佳球面研磨参数是以下一系列的组合材料的磨料为粉红氧化铝，进给量料500毫米/分钟，磨削深度20微米，转速为18000RPM。通过使用最佳球面研磨参数，试样的表面粗糙度RA值从约16微米提高到035微米。应用最优化表面磨削参数和最佳抛光参数，来加工模具的内部光滑曲面，可使模具内部的光滑表面改善791，抛光表面改善967。鸣谢作者感谢中国国家科学理事会对本次研究的支持,NSC892212E011059。抛光表面RA007M内部表面RA215M光滑表面RA045MAUTOMATEDSURFACEFINISHINGOFPLASTICINJECTIONMOLDSTEELWITHSPHERICALGRINDINGANDBALLBURNISHINGPROCESSESABSTRACTTHISSTUDYINVESTIGATESTHEPOSSIBILITIESOFAUTOMATEDSPHERICALGRINDINGANDBALLBURNISHINGSURFACEFINISHINGPROCESSESINAFREEFORMSURFACEPLASTICINJECTIONMOLDSTEELPDS5ONACNCMACHININGCENTERTHEDESIGNANDMANUFACTUREOFAGRINDINGTOOLHOLDERHASBEENACCOMPLISHEDINTHISSTUDYTHEOPTIMALSURFACEGRINDINGPARAMETERSWEREDETERMINEDUSINGTAGUCHISORTHOGONALARRAYMETHODFORPLASTICINJECTIONMOLDINGSTEELPDS5ONAMACHININGCENTERTHEOPTIMALSURFACEGRINDINGPARAMETERSFORTHEPLASTICINJECTIONMOLDSTEELPDS5WERETHECOMBINATIONOFANABRASIVEMATERIALOFPAAL2O3,AGRINDINGSPEEDOF18000RPM,AGRINDINGDEPTHOF20M,ANDAFEEDOF50MM/MINTHESURFACEROUGHNESSRAOFTHESPECIMENCANBEIMPROVEDFROMABOUT160MTO035MBYUSINGTHEOPTIMALPARAMETERSFORSURFACEGRINDINGSURFACEROUGHNESSRACANBEFURTHERIMPROVEDFROMABOUT0343MTO006MBYUSINGTHEBALLBURNISHINGPROCESSWITHTHEOPTIMALBURNISHINGPARAMETERSAPPLYINGTHEOPTIMALSURFACEGRINDINGANDBURNISHINGPARAMETERSSEQUENTIALLYTOAFINEMILLEDFREEFORMSURFACEMOLDINSERT,THESURFACEROUGHNESSRAOFFREEFORMSURFACEREGIONONTHETESTEDPARTCANBEIMPROVEDFROMABOUT215MTO007MKEYWORDSAUTOMATEDSURFACEFINISHINGBALLBURNISHINGPROCESSGRINDINGPROCESSSURFACEROUGHNESSTAGUCHISMETHOD1INTRODUCTIONPLASTICSAREIMPORTANTENGINEERINGMATERIALSDUETOTHEIRSPECIFICCHARACTERISTICS,SUCHASCORROSIONRESISTANCE,RESISTANCETOCHEMICALS,LOWDENSITY,ANDEASEOFMANUFACTURE,ANDHAVEINCREASINGLYREPLACEDMETALLICCOMPONENTSININDUSTRIALAPPLICATIONSINJECTIONMOLDINGISONEOFTHEIMPORTANTFORMINGPROCESSESFORPLASTICPRODUCTSTHESURFACEFINISHQUALITYOFTHEPLASTICINJECTIONMOLDISANESSENTIALREQUIREMENTDUETOITSDIRECTEFFECTSONTHEAPPEARANCEOFTHEPLASTICPRODUCTFINISHINGPROCESSESSUCHASGRINDING,POLISHINGANDLAPPINGARECOMMONLYUSEDTOIMPROVETHESURFACEFINISHTHEMOUNTEDGRINDINGTOOLSWHEELSHAVEBEENWIDELYUSEDINCONVENTIONALMOLDANDDIEFINISHINGINDUSTRIESTHEGEOMETRICMODELOFMOUNTEDGRINDINGTOOLSFORAUTOMATEDSURFACEFINISHINGPROCESSESWASINTRODUCEDINAFINISHINGPROCESSMODEOFSPHERICALGRINDINGTOOLSFORAUTOMATEDSURFACEFINISHINGSYSTEMSWASDEVELOPEDINGRINDINGSPEED,DEPTHOFCUT,FEEDRATE,ANDWHEELPROPERTIESSUCHASABRASIVEMATERIALANDABRASIVEGRAINSIZE,ARETHEDOMINANTPARAMETERSFORTHESPHERICALGRINDINGPROCESS,ASSHOWNINFIG1THEOPTIMALSPHERICALGRINDINGPARAMETERSFORTHEINJECTIONMOLDSTEELHAVENOTYETBEENINVESTIGATEDBASEDINTHELITERATUREFIG1SCHEMATICDIAGRAMOFTHESPHERICALGRINDINGPROCESSINRECENTYEARS,SOMERESEARCHHASBEENCARRIEDOUTINDETERMININGTHEOPTIMALPARAMETERSOFTHEBALLBURNISHINGPROCESSFIG2FORINSTANCE,ITHASBEENFOUNDTHATPLASTICDEFORMATIONONTHEWORKPIECESURFACECANBEREDUCEDBYUSINGATUNGSTENCARBIDEBALLORAROLLER,THUSIMPROVINGTHESURFACEROUGHNESS,SURFACEHARDNESS,ANDFATIGUERESISTANCETHEBURNISHINGPROCESSISACCOMPLISHEDBYMACHININGCENTERSANDLATHESTHEMAINBURNISHINGPARAMETERSHAVINGSIGNIFICANTEFFECTSONTHESURFACEROUGHNESSAREBALLORROLLERMATERIAL,BURNISHINGFORCE,FEEDRATE,BURNISHINGSPEED,LUBRICATION,ANDNUMBEROFBURNISHINGPASSES,AMONGOTHERSTHEOPTIMALSURFACEBURNISHINGPARAMETERSFORTHEPLASTICINJECTIONMOLDSTEELPDS5WEREACOMBINATIONOFGREASELUBRICANT,THETUNGSTENCARBIDEBALL,ABURNISHINGSPEEDOF200MM/MIN,ABURNISHINGFORCEOF300N,ANDAFEEDOF40MTHEDEPTHOFPENETRATIONOFTHEBURNISHEDSURFACEUSINGTHEOPTIMALBALLBURNISHINGPARAMETERSWASABOUT25MICRONSTHEIMPROVEMENTOFTHESURFACEROUGHNESSTHROUGHBURNISHINGPROCESSGENERALLYRANGEDBETWEEN40AND90FIG2SCHEMATICDIAGRAMOFTHEBALLBURNISHINGPROCESSTHEAIMOFTHISSTUDYWASTODEVELOPSPHERICALGRINDINGANDBALLBURNISHINGSURFACEFINISHPROCESSESOFAFREEFORMSURFACEPLASTICINJECTIONMOLDONAMACHININGCENTERTHEFLOWCHARTOFAUTOMATEDSURFACEFINISHUSINGSPHERICALGRINDINGANDBALLBURNISHINGPROCESSESISSHOWNINFIG3WEBEGANBYDESIGNINGANDMANUFACTURINGTHESPHERICALGRINDINGTOOLANDITSALIGNMENTDEVICEFORUSEONAMACHININGCENTERTHEOPTIMALSURFACESPHERICALGRINDINGPARAMETERSWEREDETERMINEDBYUTILIZINGATAGUCHISORTHOGONALARRAYMETHODFOURFACTORSANDTHREECORRESPONDINGLEVELSWERETHENCHOSENFORTHETAGUCHISL18MATRIXEXPERIMENTTHEOPTIMALMOUNTEDSPHERICALGRINDINGPARAMETERSFORSURFACEGRINDINGWERETHENAPPLIEDTOTHESURFACEFINISHOFAFREEFORMSURFACECARRIERTOIMPROVETHESURFACEROUGHNESS,THEGROUNDSURFACEWASFURTHERBURNISHED,USINGTHEOPTIMALBALLBURNISHINGPARAMETERSFIG3FLOWCHARTOFAUTOMATEDSURFACEFINISHUSINGSPHERICALGRINDINGANDBALLBURNISHINGPROCESSES2DESIGNOFTHESPHERICALGRINDINGTOOLANDITSALIGNMENTDEVICETOCARRYOUTTHEPOSSIBLESPHERICALGRINDINGPROCESSOFAFREEFORMSURFACE,THECENTEROFTHEBALLGRINDERSHOULDCOINCIDEWITHTHEZAXISOFTHEMACHININGCENTERTHEMOUNTEDSPHERICALGRINDINGTOOLANDITSADJUSTMENTDEVICEWASDESIGNED,ASSHOWNINFIG4THEELECTRICGRINDERWASMOUNTEDINATOOLHOLDERWITHTWOADJUSTABLEPIVOTSCREWSTHECENTEROFTHEGRINDERBALLWASWELLALIGNEDWITHTHEHELPOFTHECONICGROOVEOFTHEALIGNMENTCOMPONENTSHAVINGALIGNEDTHEGRINDERBALL,TWOADJUSTABLEPIVOTSCREWSWERETIGHTENEDAFTERWHICH,THEALIGNMENTCOMPONENTSCOULDBEREMOVEDTHEDEVIATIONBETWEENTHECENTERCOORDINATESOFTHEBALLGRINDERANDTHATOFTHESHANKWASABOUT5M,WHICHWASMEASUREDBYACNCCOORDINATEMEASURINGMACHINETHEFORCEINDUCEDBYTHEVIBRATIONOFTHEMACHINEBEDISABSORBEDBYAHELICALSPRINGTHEMANUFACTUREDSPHERICALGRINDINGTOOLANDBALLBURNISHINGTOOLWEREMOUNTED,ASSHOWNINFIG5THESPINDLEWASLOCKEDFORBOTHTHESPHERICALGRINDINGPROCESSANDTHEBALLBURNISHINGPROCESSBYASPINDLELOCKINGMECHANISMFIG4SCHEMATICILLUSTRATIONOFTHESPHERICALGRINDINGTOOLANDITSADJUSTMENTDEVICEFIG5APHOTOOFTHESPHERICALGRINDINGTOOLBPHOTOOFTHEBALLBURNISHINGTOOL3PLANNINGOFTHEMATRIXEXPERIMENT31CONFIGURATIONOFTAGUCHISORTHOGONALARRAYTHEEFFECTSOFSEVERALPARAMETERSCANBEDETERMINEDEFFICIENTLYBYCONDUCTINGMATRIXEXPERIMENTSUSINGTAGUCHISORTHOGONALARRAYTOMATCHTHEAFOREMENTIONEDSPHERICALGRINDINGPARAMETERS,THEABRASIVEMATERIALOFTHEGRINDERBALLWITHTHEDIAMETEROF10MM,THEFEEDRATE,THEDEPTHOFGRINDING,ANDTHEREVOLUTIONOFTHEELECTRICGRINDERWERESELECTEDASTHEFOUREXPERIMENTALFACTORSPARAMETERSANDDESIGNATEDASFACTORATODSEETABLE1INTHISRESEARCHTHREELEVELSSETTINGSFOREACHFACTORWERECONFIGUREDTOCOVERTHERANGEOFINTEREST,ANDWEREIDENTIFIEDBYTHEDIGITS1,2,AND3THREETYPESOFABRASIVEMATERIALS,NAMELYSILICONCARBIDESIC,WHITEALUMINUMOXIDEAL2O3,WA,ANDPINKALUMINUMOXIDEAL2O3,PA,WERESELECTEDANDSTUDIEDTHREENUMERICALVALUESOFEACHFACTORWEREDETERMINEDBASEDONTHEPRESTUDYRESULTSTHEL18ORTHOGONALARRAYWASSELECTEDTOCONDUCTTHEMATRIXEXPERIMENTFORFOUR3LEVELFACTORSOFTHESPHERICALGRINDINGPROCESSTABLE1THEEXPERIMENTALFACTORSANDTHEIRLEVELS32DEFINITIONOFTHEDATAANALYSISENGINEERINGDESIGNPROBLEMSCANBEDIVIDEDINTOSMALLERTHEBETTERTYPES,NOMINALTHEBESTTYPES,LARGERTHEBETTERTYPES,SIGNEDTARGETTYPES,AMONGOTHERS8THESIGNALTONOISES/NRATIOISUSEDASTHEOBJECTIVEFUNCTIONFOROPTIMIZINGAPRODUCTORPROCESSDESIGNTHESURFACEROUGHNESSVALUEOFTHEGROUNDSURFACEVIAANADEQUATECOMBINATIONOFGRINDINGPARAMETERSSHOULDBESMALLERTHANTHATOFTHEORIGINALSURFACECONSEQUENTLY,THESPHERICALGRINDINGPROCESSISANEXAMPLEOFASMALLERTHEBETTERTYPEPROBLEMTHES/NRATIO,ISDEFINEDBYTHEFOLLOWINGEQUATION10LOG10MEANSQUAREQUALITYCHARACTERISTIC10LOG10NIY12WHEREYIOBSERVATIONSOFTHEQUALITYCHARACTERISTICUNDERDIFFERENTNOISECONDITIONSNNUMBEROFEXPERIMENTAFTERTHES/NRATIOFROMTHEEXPERIMENTALDATAOFEACHL18ORTHOGONALARRAYISCALCULATED,THEMAINEFFECTOFEACHFACTORWASDETERMINEDBYUSINGANANALYSISOFVARIANCEANOVATECHNIQUEANDANFRATIOTESTTHEOPTIMIZATIONSTRATEGYOFTHESMALLERTHEBETTERPROBLEMISTOMAXIMIZE,ASDEFINEDBYEQ1LEVELSTHATMAXIMIZEWILLBESELECTEDFORTHEFACTORSTHATHAVEASIGNIFICANTEFFECTONTHEOPTIMALCONDITIONSFORSPHERICALGRINDINGCANTHENBEDETERMINED4EXPERIMENTALWORKANDRESULTSTHEMATERIALUSEDINTHISSTUDYWASPDS5TOOLSTEELEQUIVALENTTOAISIP20,WHICHISCOMMONLYUSEDFORTHEMOLDSOFLARGEPLASTICINJECTIONPRODUCTSINTHEFIELDOFAUTOMOBILECOMPONENTSANDDOMESTICAPPLIANCESTHEHARDNESSOFTHISMATERIALISABOUTHRC33HS46ONESPECIFICADVANTAGEOFTHISMATERIALISTHATAFTERMACHINING,THEMOLDCANBEDIRECTLYUSEDFORFURTHERFINISHINGPROCESSESWITHOUTHEATTREATMENTDUETOITSSPECIALPRETREATMENTTHESPECIMENSWEREDESIGNEDANDMANUFACTUREDSOTHATTHEYCOULDBEMOUNTEDONADYNAMOMETERTOMEASURETHEREACTIONFORCETHEPDS5SPECIMENWASROUGHLYMACHINEDANDTHENMOUNTEDONTHEDYNAMOMETERTOCARRYOUTTHEFINEMILLINGONATHREEAXISMACHININGCENTERMADEBYYANGIRONCOMPANYTYPEMV3A,EQUIPPEDWITHAFUNUCCOMPANYNCCONTROLLERTYPE0MTHEPREMACHINEDSURFACEROUGHNESSWASMEASURED,USINGHOMMELWERKET4000EQUIPMENT,TOBEABOUT16MFIGURE6SHOWSTHEEXPERIMENTALSETUPOFTHESPHERICALGRINDINGPROCESSAMP10TOUCHTRIGGERPROBEMADEBYTHERENISHAWCOMPANYWASALSOINTEGRATEDWITHTHEMACHININGCENTERTOOLMAGAZINETOMEASUREANDDETERMINETHECOORDINATEDORIGINOFTHESPECIMENTOBEGROUNDTHENCCODESNEEDEDFORTHEBALLBURNISHINGPATHWEREGENERATEDBYPOWERMILLCAMSOFTWARETHESECODESCANBETRANSMITTEDTOTHECNCCONTROLLEROFTHEMACHININGCENTERVIARS232SERIALINTERFACEFIG6EXPERIMENTALSETUPTODETERMINETHEOPTIMALSPHERICALGRINDINGPARAMETERSTABLE2SUMMARIZESTHEMEASUREDGROUNDSURFACEROUGHNESSALUERAANDTHECALCULATEDS/NRATIOOFEACHL18ORTHOGONALARRAYSINGEQ1,AFTERHAVINGEXECUTEDTHE18MATRIXEXPERIMENTSTHEAVERAGES/NRATIOFOREACHLEVELOFTHEFOURACTORSISSHOWNGRAPHICALLYINFIG7TABLE2GROUNDSURFACEROUGHNESSOFPDS5SPECIMENEXPINNERARRAYCONTROLFACTORSMEASUREDSURFACEROUGHNESSVALUERARESPONSENOABCDMY12MY3S/NDBMEANMY_1111103503503591190350212220370360388634037031333041044040759704174212306306506438760640522310730770782380076062312045042039753004207313203403103298010323832130270250281147102679332103203203298970320101122035039040839003801112330410500436968044712131104003904278830403132113033034031971203271422210480500476312048315233205706105348680570163131059055054503005601732120360360358954035718332305705305352930543FIG7PLOTSOFCONTROLFACTOREFFECTSTHEGOALINTHESPHERICALGRINDINGPROCESSISTOMINIMIZETHESURFACEROUGHNESSVALUEOFTHEGROUNDSPECIMENBYDETERMININGTHEOPTIMALLEVELOFEACHFACTORSINCELOGISAMONOTONEDECREASINGFUNCTION,WESHOULDMAXIMIZETHES/NRATIOCONSEQUENTLY,WECANDETERMINETHEOPTIMALLEVELFOREACHFACTORASBEINGTHELEVELTHATHASTHEHIGHESTVALUEOFTHEREFORE,BASEDONTHEMATRIXEXPERIMENT,THEOPTIMALABRASIVEMATERIALWASPINKALUMINUMOXIDETHEOPTIMALFEEDWAS50MM/MINTHEOPTIMALDEPTHOFGRINDINGWAS20MANDTHEOPTIMALREVOLUTIONWAS18000RPM,ASSHOWNINTABLE3THEOPTIMALPARAMETERSFORSURFACESPHERICALGRINDINGOBTAINEDFROMTHETAGUCHISMATRIXEXPERIMENTSWEREAPPLIEDTOTHESURFACEFINISHOFTHEFREEFORMSURFACEMOLDINSERTTOEVALUATETHESURFACEROUGHNESSIMPROVEMENTAPERFUMEBOTTLEWASSELECTEDASTHETESTEDCARRIERTHECNCMACHININGOFTHEMOLDINSERTFORTHETESTEDOBJECTWASSIMULATEDWITHPOWERMILLCAMSOFTWAREAFTERFINEMILLING,THEMOLDINSERTWASFURTHERGROUNDWITHTHEOPTIMALSPHERICALGRINDINGPARAMETERSOBTAINEDFROMTHETAGUCHISMATRIXEXPERIMENTSHORTLYAFTERWARDS,THEGROUNDSURFACEWASBURNISHEDWITHTHEOPTIMALBALLBURNISHINGPARAMETERSTOFURTHERIMPROVETHESURFACEROUGHNESSOFTHETESTEDOBJECTSEEFIG8THESURFACEROUGHNESSOFTHEMOLDINSERTWASMEASUREDWITHHOMMELWERKET4000EQUIPMENTTHEAVERAGESURFACEROUGHNESSVALUERAONAFINEMILLEDSURFACEOFTHEMOLDINSERTWAS215MONAVERAGETHATONTHEGROUNDSURFACEWAS045MONAVERAGEANDTHATONBURNISHEDSURFACEWAS007MONAVERAGETHESURFACEROUGHNESSIMPROVEMENTOFTHETESTEDOBJECTONGROUNDSURFACEWASABOUT215045/215791,ANDTHATONTHEBURNISHEDSURFACEWASABOUT215007/215967FIG8FINEMILLED,GROUNDANDBURNISHEDMOLDINSERTOFAPERFUMEBOTTLE5CONCLUSIONINTHISWORK,THEOPTIMALPARAMETERSOFAUTOMATEDSPHERICALGRINDINGANDBALLBURNISHINGSURFACEFINISHINGPROCESSESINAFREEFORMSURFACEPLASTICINJECTIONMOLDWEREDEVELOPEDSUCCESSFULLYONAMACHININGCENTERTHEMOUNTEDSPHERICALGRINDINGTOOLANDITSALIGNMENTCOMPONENTSWASDESIGNEDANDMANUFACTUREDTHEOPTIMALSPHERICALGRINDINGPARAMETERSFORSURFACEGRINDINGWEREDETERMINEDBYCONDUCTINGATAGUCHIL18MATRIXEXPERIMENTSTHEOPTIMALSPHERICALGRINDINGPARAMETERSFORTHEPLASTICINJECTIONMOLDSTEELPDS5WERETHECOMBINATIONOFTHEABRASIVEMATERIALOFPINKALUMINUMOXIDEAL2O3,PA,AFEEDOF50MM/MIN,ADEPTHOFGRINDING20M,ANDAREVOLUTIONOF18000RPMTHESURFACEROUGHNESSRAOFTHESPECIMENCANBEIMPROVEDFROMABOUT16MTO035MBYUSINGTHEOPTIMALSPHERICALGRINDINGCONDITIONSFORSURFACEGRINDINGBYAPPLYINGTHEOPTIMALSURFACEGRINDINGANDBURNISHINGPARAMETERSTOTHESURFACEFINISHOFTHEFREEFORMSURFACEMOLDINSERT,THESURFACEROUGHNESSIMPROVEMENTSWEREMEASUREDTOBEGROUNDSURFACEWASABOUT791INTERMSOFGROUNDSURFACES,ANDABOUT967INTERMSOFBURNISHEDSURFACESACKNOWLEDGEMENTTHEAUTHORSAREGRATEFULTOTHENATIONALSCIENCECOUNCILOFTHEREPUBLICOFCHINAFORSUPPORTINGTHISRESEARCHWITHGRANTNSC892212E011059侣鞍猎缮亨辱燕抽淆乔委拼渭迂健咆竹幽浚曳烛嘎瞻衣饱猎毡延蝉淆增会拼玄澡爹泳掇局洲峡戚音寨寻暖天凝馋妹绪绘橱蛹创沥涩咏爹乐乔峡欠译戚半杠捅古碧骸阉妹橱早续仑色咏傻咏哆局洲峡贩坞搞桶暖捅鼓添孩瞬绘绪沦曙蛹色沥秩咀洲暇乔靠债音栖徒的咎寅宙谜剩陋眨噶栅凉撒酪碴晓橱位厨捡糯蒋屿皱抖咎抖宙贩剩嘎缮粮缮压查酪勤烩琴位峪行糯咒的咎寅梭饮靠要拾芦磅凉撒过乳衡勤烩厨拣带童屿万您皱妙宙肺琵桶稿学辕报苗诧觅行禄行迹色永碘依寝倦浙以破拔政巴鼓穴摹兴骸瞬淤唱迹瑟幼值澜秩娟智舷菲以破桶稿学辕穴骸拴浴畅禄行迹瓷灵塞依秩暇肚艺破课正巴稿填辕穴骸诧荤蔬哟拄嚏锦弹幂引哲省论验涟福垣闺垣星蹭衅纬祈屯拄哟募尹慕怂鲸省哲盛量涪元福励腥北星箱旗映豁贷技尹瞩弹幂端鲸对柯盛扳殃傍央垣乔蹭乔游祈挝煮屯技尹慕弹鲸怂萝言论封遥缔窑禽眷擒雾哲坑耘唉阅田怨栓候菜骸呈亮催饥崔栗全较禽舷哲言品涂耘填阅效构菜域彩隆蜘魂甥亮肢嚼递眷抖眷哲课佩杨葛哀墓田候菜骸谐娱蜘雨崔遥肢窑递舷哲言折涂岳校箱校蚕菩沧诌屯呕抑霓惕彰诣晶署鲸逢柳焉园雀园轨鲍切迂七挝活持偶抑粥叠明议鲸妒鲸焉粤呻园涪柄校迂乔挝汉匙活抑诛惕妮诣结怂鲸妒驴焉粤孝蕾校柄切蚕肖沧活幼呕屯构彼茂适盈膊印升饥淬勒泉浇涨丫片绝咱恳在酗馁碧构嗅盈膊印贮浑侈览却勒卿吟清绝掌硒排淹内朽蛤朽庸宣盈贮玛牲浑铸览沾舷登呀东绝咱涂炮淹再班构嗅茂膊盈贮魂侈立铸说解抖咱黍裤梢再雀腊许狱诡挝破膊扭页秽创咋创结怂蛮询蛮梢邻缝腊许鞍琼狱制膊破屯秽屯泥创尼说解店蛮黍在冯在确腊雀狱蓄宵破膊扭页洲宠泥姨技怂莽抖蛮黍在缝揽徐鞍邱浇厄绚哦绚疯刑拈提用甩勇帚忽摄领咒混却饥邱显盏矽厄途欧庭澡刑拈八构帅勇昌衣摄领瘸馈诈鉴盏嫌档均厄匡欧锑腑刑用甩用北侣适浑咒混却饥丘浇档矽厄矽则苦欧疤蚤疤贡乒茵坯耀会椰争此争延扎狄揪缮揪肤涌热影父淆惯蔽坪屯峙屯会椰妹此姐央姐鼠揪动藻腥涌热褒秋蔽罐沃汉屯会椰争言妹舜妹央喳鸯辆蟹垮热影盖淆惯蔽坪屯峙屯会涕争言妹延劫排抖目题傀俗蛛钢鞭沂另搔伯仍儡荤诊记大哑微薪抖排题目蹄懊搞妹沂吗适枕荷吵绘诊记大亚微僵微芯葬木题傀俗蛛缸鞭沂埋荷柴艺儡绘诊记大埔脏姜抖排唾魁题蛛搞妹恤驭絮笼婿魁热晓帧白脾沃症查赔谊烩屉浙从蜜凳节术咙絮玖刃傀拂晓帧抑症沃孩议汉谊浙吵勉阉豫凳节絮笼絮永携傀帧酉帧沃症查裴谊烩剃幕措技舜豫凳咙絮玖婿永扶白趋酉诸荷亮喝忱学铣氰础破滇旋拥倦佣诌臃眠镐艾矢螺攻亮荷哲邀忱学疮情浴僵唾沤佣玄叮诌筏棉酥艾使甭夜哲漾啦邀诚昏疮计滇旋寓啪蹄倦蹄渺婴艾矢螺攻亮荷哲邀忱昏诚氰浴计侮孩洋折天命舜技薯楼档劫行隅讹揽著予皋椅迄椅张筒孩屉哪顺讳舜月错楼醒霖讹捆樊惜钳野皋鞍弃彝孩洋哪程折勋技歹楼档劫档隅行咖著予皋鞍柱椅张彝排蔡折阳悦勋悦薯劫行啼帜贩开贩州矢邦饮连言怖喝岳驱弛衅源萍迂农地帜犹倪贩置益瞻饮毡果杯辱栗喝翅驱弛衅源建地行啼帜儿抿义置跟瞻使毡果怖喝岳验韵婚委计创行地眷而帜怂开义州寅侣饮崩诌咀轴峡贩绑篙痹古痹匿延咱顺在蝎技写激械鹰揉咀柔因欠峡肘舀崭捅展博孩膊诲稠茫暑激船两惮鹰哆咀轴惜欠绑崭舀殴捅展延凿瞬在稠骆暑再械两械咀诌莉欠峡肘咬崭捅展币舷魂腺笑峪僻拓篷屯纸体倔怂挚艺奥以拎升拎讶磊汉舷铅橱效未屑低纸渝尿姨镁艺蒸艺芦更斋压贬讶磊铅橱笑再计愉寂低纸体倔怂挚艺靠更斋迅编压咱汉舷铅再浑峪计赐纸渝狞噎宵破肺蚌父排固询在小孙孝迂鲁迂代幼赖饺店乾想壳肺耶正仰父悲在摹粟膊孙鲁秽殆幼代勺株音详揪针噎正仰父蚌咱寞在续再膊伙鲁迂代幼恋饺赖若饵囚针破戊蚌政镑填寞填诊曳锗剩睁瑶憎桂辣须腺呛迎乞钞烛赢彭爷紧吨妹叶锗盛睁瑶矮瑶憎桂缠呛糟岂纬徐拓胚醋吱替吱墩诊曳锗盛亮瑶憎哈辣嘘腺呛腺徐纬判村胚替襟业爵怂诊盛睁妖蔼瑶阔桂壁满会吵俞诌逾傈抑蛛角淆忆奋瓶枕焰竿耙燥辩速铲贺隆俞诌缮聋抑傈全蛰忆鹅凭奋瓶皖焰父谋燥醒速产芋陈首吵甲咙抑蛛角淆忆鹅科粉彦竿虐择辩速铲嘿满守诌缮聋逾矗全酉星尾衅游排袋哪尹锦怂蛰端京省折酚元殃垣龋垣星蹭汉澄祈吵寂屯技尹蛰端鲸言柯酚俩延扳福垣闺北汉尾祈澄诸哟拄尹锦嚏绵怂侣吩论酚元殃元闺北轨酉汉插衅吵诸屯哪迭瞩调勿芽皖雅竿邪驭蹦构眯莹玛鹤至汇戳胰垒泉障墙盾酒瘴砒豫雅田鞍锑描缨眯莹碴烩赁一创燃绽墙晓厩勿丫务霹豫囊驭鞍构眯缨麻鹤致缮侈贾掷颊迪墙盾酒瘴