机械外文翻译文献翻译球形研磨和抛光注塑模具钢的自动化表面精加工工艺

GRINGINGTECHNOLOGY磨削技术,1994STEPHENMALKIN原文题目AUTOMATEDSURFACEFINISHINGOFPLASTICINJECTIONMOLDSTEELWITHSPHERICALGRINDINGANDBALLBURNISHINGPROCESSESABSTRACTTHISSTUDYINVESTIGATESTHEPOSSIBILITIESOFAUTOMATEDSPHERICALGRINDINGANDBALLBURNISHINGSURFACEFINISHINGPROCESSESINAFREEFORMSURFACEPLASTICINJECTIONMOLDSTEELPDS5ONACNCMACHININGCENTERTHEDESIGNANDMANUFACTUREOFAGRINDINGTOOLHOLDERHASBEENACCOMPLISHEDINTHISSTUDYTHEOPTIMALSURFACEGRINDINGPARAMETERSWEREDETERMINEDUSINGTAGUCHISORTHOGONALARRAYMETHODFORPLASTICINJECTIONMOLDINGSTEELPDS5ONAMACHININGCENTERTHEOPTIMALSURFACEGRINDINGPARAMETERSFORTHEPLASTICINJECTIONMOLDSTEELPDS5WERETHECOMBINATIONOFANABRASIVEMATERIALOFPAAL2O3,AGRINDINGSPEEDOF18000RPM,AGRINDINGDEPTHOF20M,ANDAFEEDOF50MM/MINTHESURFACEROUGHNESSRAOFTHESPECIMENCANBEIMPROVEDFROMABOUT160MTO035MBYUSINGTHEOPTIMALPARAMETERSFORSURFACEGRINDINGSURFACEROUGHNESSRACANBEFURTHERIMPROVEDFROMABOUT0343MTO006MBYUSINGTHEBALLBURNISHINGPROCESSWITHTHEOPTIMALBURNISHINGPARAMETERSAPPLYINGTHEOPTIMALSURFACEGRINDINGANDBURNISHINGPARAMETERSSEQUENTIALLYTOAFINEMILLEDFREEFORMSURFACEMOLDINSERT,THESURFACEROUGHNESSRAOFFREEFORMSURFACEREGIONONTHETESTEDPARTCANBEIMPROVEDFROMABOUT215MTO007MKEYWORDSAUTOMATEDSURFACEFINISHINGBALLBURNISHINGPROCESSGRINDINGPROCESSSURFACEROUGHNESSTAGUCHISMETHOD1INTRODUCTIONPLASTICSAREIMPORTANTENGINEERINGMATERIALSDUETOTHEIRSPECIFICCHARACTERISTICS,SUCHASCORROSIONRESISTANCE,RESISTANCETOCHEMICALS,LOWDENSITY,ANDEASEOFMANUFACTURE,ANDHAVEINCREASINGLYREPLACEDMETALLICCOMPONENTSININDUSTRIALAPPLICATIONSINJECTIONMOLDINGISONEOFTHEIMPORTANTFORMINGPROCESSESFORPLASTICPRODUCTSTHESURFACEFINISHQUALITYOFTHEPLASTICINJECTIONMOLDISANESSENTIALREQUIREMENTDUETOITSDIRECTEFFECTSONTHEAPPEARANCEOFTHEPLASTICPRODUCTFINISHINGPROCESSESSUCHASGRINDING,POLISHINGANDLAPPINGARECOMMONLYUSEDTOIMPROVETHESURFACEFINISHTHEMOUNTEDGRINDINGTOOLSWHEELSHAVEBEENWIDELYUSEDINCONVENTIONALMOLDANDDIEFINISHINGINDUSTRIESTHEGEOMETRICMODELOFMOUNTEDGRINDINGTOOLSFORAUTOMATEDSURFACEFINISHINGPROCESSESWASINTRODUCEDIN1AFINISHINGPROCESSMODELOFSPHERICALGRINDINGTOOLSFORAUTOMATEDSURFACEFINISHINGSYSTEMSWASDEVELOPEDIN2GRINDINGSPEED,DEPTHOFCUT,FEEDRATE,ANDWHEELPROPERTIESSUCHASABRASIVEMATERIALANDABRASIVEGRAINSIZE,ARETHEDOMINANTPARAMETERSFORTHESPHERICALGRINDINGPROCESS,ASSHOWNINFIG1THEOPTIMALSPHERICALGRINDINGPARAMETERSFORTHEINJECTIONMOLDSTEELHAVENOTYETBEENINVESTIGATEDBASEDINTHELITERATUREINRECENTYEARS,SOMERESEARCHHASBEENCARRIEDOUTINDETERMININGTHEOPTIMALPARAMETERSOFTHEBALLBURNISHINGPROCESSFIG2FORINSTANCE,ITHASBEENFOUNDTHATPLASTICDEFORMATIONONTHEWORKPIECESURFACECANBEREDUCEDBYUSINGATUNGSTENCARBIDEBALLORAROLLER,THUSIMPROVINGTHESURFACEROUGHNESS,SURFACEHARDNESS,ANDFATIGUERESISTANCE36THEBURNISHINGPROCESSISACCOMPLISHEDBYMACHININGCENTERS3,4ANDLATHES5,6THEMAINBURNISHINGPARAMETERSHAVINGSIGNIFICANTEFFECTSONTHESURFACEROUGHNESSAREBALLORROLLERMATERIAL,BURNISHINGFORCE,FEEDRATE,BURNISHINGSPEED,LUBRICATION,ANDNUMBEROFBURNISHINGPASSES,AMONGOTHERS3THEOPTIMALSURFACEBURNISHINGPARAMETERSFORTHEPLASTICINJECTIONMOLDSTEELPDS5WEREACOMBINATIONOFGREASELUBRICANT,THETUNGSTENCARBIDEBALL,ABURNISHINGSPEEDOF200MM/MIN,ABURNISHINGFORCEOF300N,ANDAFEEDOF40M7THEDEPTHOFPENETRATIONOFTHEBURNISHEDSURFACEUSINGTHEOPTIMALBALLBURNISHINGPARAMETERSWASABOUT25MICRONSTHEIMPROVEMENTOFTHESURFACEROUGHNESSTHROUGHBURNISHINGPROCESSGENERALLYRANGEDBETWEEN40AND9037THEAIMOFTHISSTUDYWASTODEVELOPSPHERICALGRINDINGANDBALLBURNISHINGSURFACEFINISHPROCESSESOFAFREEFORMSURFACEPLASTICINJECTIONMOLDONAMACHININGCENTERTHEFLOWCHARTOFAUTOMATEDSURFACEFINISHUSINGSPHERICALGRINDINGANDBALLBURNISHINGPROCESSESISSHOWNINFIG3WEBEGANBYDESIGNINGANDMANUFACTURINGTHESPHERICALGRINDINGTOOLANDITSALIGNMENTDEVICEFORUSEONAMACHININGCENTERTHEOPTIMALSURFACESPHERICALGRINDINGPARAMETERSWEREDETERMINEDBYUTILIZINGATAGUCHISORTHOGONALARRAYMETHODFOURFACTORSANDTHREECORRESPONDINGLEVELSWERETHENCHOSENFORTHETAGUCHISL18MATRIXEXPERIMENTTHEOPTIMALMOUNTEDSPHERICALGRINDINGPARAMETERSFORSURFACEGRINDINGWERETHENAPPLIEDTOTHESURFACEFINISHOFAFREEFORMSURFACECARRIERTOIMPROVETHESURFACEROUGHNESS,THEGROUNDSURFACEWASFURTHERBURNISHED,USINGTHEOPTIMALBALLBURNISHINGPARAMETERS2DESIGNOFTHESPHERICALGRINDINGTOOLANDITSALIGNMENTDEVICETOCARRYOUTTHEPOSSIBLESPHERICALGRINDINGPROCESSOFAFREEFORMSURFACE,THECENTEROFTHEBALLGRINDERSHOULDCOINCIDEWITHTHEZAXISOFTHEMACHININGCENTERTHEMOUNTEDSPHERICALGRINDINGTOOLANDITSADJUSTMENTDEVICEWASDESIGNED,ASSHOWNINFIG4THEELECTRICGRINDERWASMOUNTEDINATOOLHOLDERWITHTWOADJUSTABLEPIVOTSCREWSTHECENTEROFTHEGRINDERBALLWASWELLALIGNEDWITHTHEHELPOFTHECONICGROOVEOFTHEALIGNMENTCOMPONENTSHAVINGALIGNEDTHEGRINDERBALL,TWOADJUSTABLEPIVOTSCREWSWERETIGHTENEDAFTERWHICH,THEALIGNMENTCOMPONENTSCOULDBEREMOVEDTHEDEVIATIONBETWEENTHECENTERCOORDINATESOFTHEBALLGRINDERANDTHATOFTHESHANKWASABOUT5M,WHICHWASMEASUREDBYACNCCOORDINATEMEASURINGMACHINETHEFORCEINDUCEDBYTHEVIBRATIONOFTHEMACHINEBEDISABSORBEDBYAHELICALSPRINGTHEMANUFACTUREDSPHERICALGRINDINGTOOLANDBALLBURNISHINGTOOLWEREMOUNTED,ASSHOWNINFIG5THESPINDLEWASLOCKEDFORBOTHTHESPHERICALGRINDINGPROCESSANDTHEBALLBURNISHINGPROCESSBYASPINDLELOCKINGMECHANISM3PLANNINGOFTHEMATRIXEXPERIMENT31CONFIGURATIONOFTAGUCHISORTHOGONALARRAYTHEEFFECTSOFSEVERALPARAMETERSCANBEDETERMINEDEFFICIENTLYBYCONDUCTINGMATRIXEXPERIMENTSUSINGTAGUCHISORTHOGONALARRAY8TOMATCHTHEAFOREMENTIONEDSPHERICALGRINDINGPARAMETERS,THEABRASIVEMATERIALOFTHEGRINDERBALLWITHTHEDIAMETEROF10MM,THEFEEDRATE,THEDEPTHOFGRINDING,ANDTHEREVOLUTIONOFTHEELECTRICGRINDERWERESELECTEDASTHEFOUREXPERIMENTALFACTORSPARAMETERSANDDESIGNATEDASFACTORATODSEETABLE1INTHISRESEARCHTHREELEVELSSETTINGSFOREACHFACTORWERECONFIGUREDTOCOVERTHERANGEOFINTEREST,ANDWEREIDENTIFIEDBYTHEDIGITS1,2,AND3THREETYPESOFABRASIVEMATERIALS,NAMELYSILICONCARBIDESIC,WHITEALUMINUMOXIDEAL2O3,WA,ANDPINKALUMINUMOXIDEAL2O3,PA,WERESELECTEDANDSTUDIEDTHREENUMERICALVALUESOFEACHFACTORWEREDETERMINEDBASEDONTHEPRESTUDYRESULTSTHEL18ORTHOGONALARRAYWASSELECTEDTOCONDUCTTHEMATRIXEXPERIMENTFORFOUR3LEVELFACTORSOFTHESPHERICALGRINDINGPROCESS32DEFINITIONOFTHEDATAANALYSISENGINEERINGDESIGNPROBLEMSCANBEDIVIDEDINTOSMALLERTHEBETTERTYPES,NOMINALTHEBESTTYPES,LARGERTHEBETTERTYPES,SIGNEDTARGETTYPES,AMONGOTHERS8THESIGNALTONOISES/NRATIOISUSEDASTHEOBJECTIVEFUNCTIONFOROPTIMIZINGAPRODUCTORPROCESSDESIGNTHESURFACEROUGHNESSVALUEOFTHEGROUNDSURFACEVIAANADEQUATECOMBINATIONOFGRINDINGPARAMETERSSHOULDBESMALLERTHANTHATOFTHEORIGINALSURFACECONSEQUENTLY,THESPHERICALGRINDINGPROCESSISANEXAMPLEOFASMALLERTHEBETTERTYPEPROBLEMTHES/NRATIO,ISDEFINEDBYTHEFOLLOWINGEQUATION8WHEREYIOBSERVATIONSOFTHEQUALITYCHARACTERISTICUNDERDIFFERENTNOISECONDITIONSNNUMBEROFEXPERIMENTAFTERTHES/NRATIOFROMTHEEXPERIMENTALDATAOFEACHL18ORTHOGONALARRAYISCALCULATED,THEMAINEFFECTOFEACHFACTORWASDETERMINEDBYUSINGANANALYSISOFVARIANCEANOVATECHNIQUEANDANFRATIOTEST8THEOPTIMIZATIONSTRATEGYOFTHESMALLERTHEBETTERPROBLEMISTOMAXIMIZE,ASDEFINEDBYEQ1LEVELSTHATMAXIMIZEWILLBESELECTEDFORTHEFACTORSTHATHAVEASIGNIFICANTEFFECTONTHEOPTIMALCONDITIONSFORSPHERICALGRINDINGCANTHENBEDETERMINED4EXPERIMENTALWORKANDRESULTSTHEMATERIALUSEDINTHISSTUDYWASPDS5TOOLSTEELEQUIVALENTTOAISIP209,WHICHISCOMMONLYUSEDFORTHEMOLDSOFLARGEPLASTICINJECTIONPRODUCTSINTHEFIELDOFAUTOMOBILECOMPONENTSANDDOMESTICAPPLIANCESTHEHARDNESSOFTHISMATERIALISABOUTHRC33HS469ONESPECIFICADVANTAGEOFTHISMATERIALISTHATAFTERMACHINING,THEMOLDCANBEDIRECTLYUSEDFORFURTHERFINISHINGPROCESSESWITHOUTHEATTREATMENTDUETOITSSPECIALPRETREATMENTTHESPECIMENSWEREDESIGNEDANDMANUFACTUREDSOTHATTHEYCOULDBEMOUNTEDONADYNAMOMETERTOMEASURETHEREACTIONFORCETHEPDS5SPECIMENWASROUGHLYMACHINEDANDTHENMOUNTEDONTHEDYNAMOMETERTOCARRYOUTTHEFINEMILLINGONATHREEAXISMACHININGCENTERMADEBYYANGIRONCOMPANYTYPEMV3A,EQUIPPEDWITHAFUNUCCOMPANYNCCONTROLLERTYPE0M10THEPREMACHINEDSURFACEROUGHNESSWASMEASURED,USINGHOMMELWERKET4000EQUIPMENT,TOBEABOUT16MFIGURE6SHOWSTHEEXPERIMENTALSETUPOFTHESPHERICALGRINDINGPROCESSAMP10TOUCHTRIGGERPROBEMADEBYTHERENISHAWCOMPANYWASALSOINTEGRATEDWITHTHEMACHININGCENTERTOOLMAGAZINETOMEASUREANDDETERMINETHECOORDINATEDORIGINOFTHESPECIMENTOBEGROUNDTHENCCODESNEEDEDFORTHEBALLBURNISHINGPATHWEREGENERATEDBYPOWERMILLCAMSOFTWARETHESECODESCANBETRANSMITTEDTOTHECNCCONTROLLEROFTHEMACHININGCENTERVIARS232SERIALINTERFACETHEGOALINTHESPHERICALGRINDINGPROCESSISTOMINIMIZETHESURFACEROUGHNESSVALUEOFTHEGROUNDSPECIMENBYDETERMININGTHEOPTIMALLEVELOFEACHFACTORSINCELOGISAMONOTONEDECREASINGFUNCTION,WESHOULDMAXIMIZETHES/NRATIOCONSEQUENTLY,WECANDETERMINETHEOPTIMALLEVELFOREACHFACTORASBEINGTHELEVELTHATHASTHEHIGHESTVALUEOFTHEREFORE,BASEDONTHEMATRIXEXPERIMENT,THEOPTIMALABRASIVEMATERIALWASPINKALUMINUMOXIDETHEOPTIMALFEEDWAS50MM/MINTHEOPTIMALDEPTHOFGRINDINGWAS20MANDTHEOPTIMALREVOLUTIONWAS18000RPM,ASSHOWNINTABLE4THEMAINEFFECTOFEACHFACTORWASFURTHERDETERMINEDBYUSINGANANALYSISOFVARIANCEANOVATECHNIQUEANDANFRATIOTESTINORDERTODETERMINETHEIRSIGNIFICANCESEETABLE5THEF010,2,13IS276FORALEVELOFSIGNIFICANCEEQUALTO010OR90CONFIDENCELEVELTHEFACTORSDEGREEOFFREEDOMIS2ANDTHEDEGREEOFFREEDOMFORTHEPOOLEDERRORIS13,ACCORDINGTOFDISTRIBUTIONTABLE11ANFRATIOVALUEGREATERTHAN276CANBECONCLUDEDASHAVINGASIGNIFICANTEFFECTONSURFACEROUGHNESSANDISIDENTIFIEDBYANASTERISKASARESULT,THEFEEDANDTHEDEPTHOFGRINDINGHAVEASIGNIFICANTEFFECTONSURFACEROUGHNESSFIVEVERIFICATIONEXPERIMENTSWERECARRIEDOUTTOOBSERVETHEREPEATABILITYOFUSINGTHEOPTIMALCOMBINATIONOFGRINDINGPARAMETERS,ASSHOWNINTABLE6THEOBTAINABLESURFACEROUGHNESSVALUERAOFSUCHSPECIMENWASMEASUREDTOBEABOUT035MSURFACEROUGHNESSWASIMPROVEDBYABOUT78INUSINGTHEOPTIMALCOMBINATIONOFSPHERICALGRINDINGPARAMETERSTHEGROUNDSURFACEWASFURTHERBURNISHEDUSINGTHEOPTIMALBALLBURNISHINGPARAMETERSASURFACEROUGHNESSVALUEOFRA006MWASOBTAINABLEAFTERBALLBURNISHINGIMPROVEMENTOFTHEBURNISHEDSURFACEROUGHNESSOBSERVEDWITHA30OPTICALMICROSCOPEISSHOWNINFIG8THEIMPROVEMENTOFPREMACHINEDSURFACESROUGHNESSWASABOUT95AFTERTHEBURNISHINGPROCESSTHEOPTIMALPARAMETERSFORSURFACESPHERICALGRINDINGOBTAINEDFROMTHETAGUCHISMATRIXEXPERIMENTSWEREAPPLIEDTOTHESURFACEFINISHOFTHEFREEFORMSURFACEMOLDINSERTTOEVALUATETHESURFACEROUGHNESSIMPROVEMENTAPERFUMEBOTTLEWASSELECTEDASTHETESTEDCARRIERTHECNCMACHININGOFTHEMOLDINSERTFORTHETESTEDOBJECTWASSIMULATEDWITHPOWERMILLCAMSOFTWAREAFTERFINEMILLING,THEMOLDINSERTWASFURTHERGROUNDWITHTHEOPTIMALSPHERICALGRINDINGPARAMETERSOBTAINEDFROMTHETAGUCHISMATRIXEXPERIMENTSHORTLYAFTERWARDS,THEGROUNDSURFACEWASBURNISHEDWITHTHEOPTIMALBALLBURNISHINGPARAMETERSTOFURTHERIMPROVETHESURFACEROUGHNESSOFTHETESTEDOBJECTSEEFIG9THESURFACEROUGHNESSOFTHEMOLDINSERTWASMEASUREDWITHHOMMELWERKET4000EQUIPMENTTHEAVERAGESURFACEROUGHNESSVALUERAONAFINEMILLEDSURFACEOFTHEMOLDINSERTWAS215MONAVERAGETHATONTHEGROUNDSURFACEWAS045MONAVERAGEANDTHATONBURNISHEDSURFACEWAS007MONAVERAGETHESURFACEROUGHNESSIMPROVEMENTOFTHETESTEDOBJECTONGROUNDSURFACEWASABOUT215045/215791,ANDTHATONTHEBURNISHEDSURFACEWASABOUT215007/2159675CONCLUSIONINTHISWORK,THEOPTIMALPARAMETERSOFAUTOMATEDSPHERICALGRINDINGANDBALLBURNISHINGSURFACEFINISHINGPROCESSESINAFREEFORMSURFACEPLASTICINJECTIONMOLDWEREDEVELOPEDSUCCESSFULLYONAMACHININGCENTERTHEMOUNTEDSPHERICALGRINDINGTOOLANDITSALIGNMENTCOMPONENTSWASDESIGNEDANDMANUFACTUREDTHEOPTIMALSPHERICALGRINDINGPARAMETERSFORSURFACEGRINDINGWEREDETERMINEDBYCONDUCTINGATAGUCHIL18MATRIXEXPERIMENTSTHEOPTIMALSPHERICALGRINDINGPARAMETERSFORTHEPLASTICINJECTIONMOLDSTEELPDS5WERETHECOMBINATIONOFTHEABRASIVEMATERIALOFPINKALUMINUMOXIDEAL2O3,PA,AFEEDOF50MM/MIN,ADEPTHOFGRINDING20M,ANDAREVOLUTIONOF18000RPMTHESURFACEROUGHNESSRAOFTHESPECIMENCANBEIMPROVEDFROMABOUT16MTO035MBYUSINGTHEOPTIMALSPHERICALGRINDINGCONDITIONSFORSURFACEGRINDINGBYAPPLYINGTHEOPTIMALSURFACEGRINDINGANDBURNISHINGPARAMETERSTOTHESURFACEFINISHOFTHEFREEFORMSURFACEMOLDINSERT,THESURFACEROUGHNESSIMPROVEMENTSWEREMEASUREDTOBEGROUNDSURFACEWASABOUT791INTERMSOFGROUNDSURFACES,ANDABOUT967INTERMSOFBURNISHEDSURFACESREFERENCES1CHENCCA,YANWS2000GEOMETRICMODELOFMOUNTEDGRINDINGTOOLSFORAUTOMATEDSURFACEFINISHINGPROCESSESINPROCEEDINGSOFTHE6THINTERNATIONALCONFERENCEONAUTOMATIONTECHNOLOGY,TAIPEI,MAY911,PP43472CHENCCA,DUFFIENA,LIUWC1997AFINISHINGMODELOFSPHERICALGRINDINGTOOLSFORAUTOMATEDSURFACEFINISHINGSYSTEMSINTJMANUFSCIPROD1117263LOHNH,TAMSC1988EFFECTSOFBALLBURNISHINGPARAMETERSONSURFACEFINISHALITERATURESURVEYANDDISCUSSIONPRECISENG1042152204LOHNH,TAMSC,MIYAZAWAS1991INVESTIGATIONSONTHESURFACEROUGHNESSPRODUCEDBYBALLBURNISHINGINTJMACHTOOLSMANUF31175815YUX,WANGL1999EFFECTOFVARIOUSPARAMETERSONTHESURFACEROUGHNESSOFANALUMINUMALLOYBURNISHEDWITHASPHERICALSURFACEDPOLYCRYSTALLINEDIAMONDTOOLINTJMACHTOOLSMANUF394594696KLOCKEF,LIERMANNJ1996ROLLERBURNISHINGOFHARDTURNEDSURFACESINTJMACHTOOLSMANUF3854194237SHIOUFJ,CHENCH2003DETERMINATIONOFOPTIMALBALLBURNISHINGPARAMETERSFORPLASTICINJECTIONMOLDINGSTEELINTJADVMANUFTECHNOL31771858PHADKEMS1989QUALITYENGINEERINGUSINGROBUSTDESIGNPRENTICEHALL,ENGLEWOODCLIFFS,NEWJERSEY9TATUNGCOMPANY1985TECHNICALHANDBOOKFORTHESELECTIONOFPLASTICINJECTIONMOLDSTEELTAIWAN10YANGIRONWORKS1996TECHNICALHANDBOOKOFMV3AVERTICALMACHININGCENTERTAIWAN11MONTGOMERYDC1991DESIGNANDANALYSISOFEXPERIMENTSWILEY,NEWYORK原文题目球形研磨和抛光注塑模具钢的自动化表面精加工工艺摘要本研究讨论在数控加工中心注塑模具钢PDS5在自由曲面下进行自动化球形研磨和抛光球的表面处理工艺的可行性。研磨工具持有人的设计和制造已经完成了这项研究。在加工中心中，表面的最佳磨削参数采用田口直交法来进行塑料注射成型钢PDS5而确定。塑料注塑模具钢PDS5表面最佳磨削参数是，一种PA的氧化铝磨削材料组合，以18000RPM的速度，20M的磨削深度，以及50毫米/分钟的进给速度磨削。试样的表面粗糙度RA可以通过使用最佳的表面磨削参数来从160微米大约提高至035微米。表面粗糙度RA还可通过使用最佳抛光参数的球抛光这一过程进一步改善至约0343微米至006微米。应用表面打磨和抛光最佳参数，依次细研磨自由曲面模仁，自由曲面上测试区的表面粗糙度RA部分可提高到约215微米至007微米。关键词自动化表面精加工球打磨过程表面粗糙度磨削工艺田口方法。1简介塑料是重要的工程材料，由于其特性，如耐腐蚀，耐化学品，密度低，易于制造，并已在工业应用中越来越多地取代金属部件。注塑成型是一种重要的塑料产品成型工艺，塑料模具表面光洁度是一个直接影响塑料产品外观的必要条件。如磨削，抛光和研磨这样的整理程序常用来改善表面光洁度。研磨工具砂轮的装入已经广泛使用的传统模具，模具加工等行业。为了自动化表面精加工进程，安装了磨削工具的几何磨具在（1）中引入。在自动化表面精加工系统中，球形研磨的球形研磨工具的加工进程模型在（2）中阐述。磨削速度，切削深度，进给速度，研磨材料，磨料，料度等砂轮特性都为球面磨削过程的影响参数，如图1所示。注塑模具钢的最佳球面磨削参数尚未在文献中调查发现。近年来，正在开展一些研究来确定球挤光过程的最佳参数（图2）。据说使用碳化钨球或滚子可减小工件表面的塑性变形，因而改善表面粗糙度，表面硬度和抗疲劳性能36。打磨过程是由加工中心3，4和车床5，6完成。对表面粗糙度有显著影响的主要抛光参数是滚珠或滚子的材料，打磨力，进给速度，抛光速度，润滑，打磨通过次数，等等3。塑料模具钢PDS5的最佳表面打磨参数是混合油脂润滑剂，碳化钨球，200毫米/分钟的磨削速度，300N的挤压力，40M打磨速度。使用最佳挤光参数的表面抛光穿透深度约为25微米。通过挤光工艺改善表面粗糙度后，介于40到90之间。这项研究的目的是在加工中心中塑料注塑磨具自由曲面的球形研磨和表面抛光加工程序的开发。使用球形表面研磨和抛光程序的自动化表面加工流程图在图3中展示。我们以设计和制造在机械加工中心中使用的球形研磨工具以及其定位装置为开始。球形表面的最佳磨削工艺参数通过利用田口直交方法来确定。在田口的18课矩阵实验中，4因素3相应水平被选择。表面磨削的最佳安装球面磨削参数被应用到自由曲面载体的表面光洁度加工中。为了改善表面粗糙度，使用最佳挤光参数来对工件表面进行进一步打磨。2设计了球形研磨工具及其定位装置为了使在自由曲面中进行球研磨加工工艺成为可能，球磨床中心应该和Z轴的加工中心形成配合，球面磨削工具的安装以及他的设备调整设计如4图所示。电动砂轮机用两个两个可调整支点螺钉安装在刀架上。在圆锥槽对齐组件的帮助下，该磨具球中心配合一致。对齐磨床球，两个可调整支点螺钉拧紧；之后，校准组件可以被移除。球磨床中心坐标之前的偏差，连杆有约5微米，这是由数控三坐标测量机测量。由机床振动引起的力被螺旋弹簧吸收。生产出来的球研磨工具和抛光球被安装如图5所示。为了球研磨过程和球挤光过程，主轴被一个主轴锁定机制锁定。3矩阵实验的规划31田口直交的配置通过进行田口直交8矩阵实验，几个参数的影响可以达到有效的使用。为配合上述球面磨削参数，该磨床球研磨材料（10毫米直径），进料速度，磨削深度,并且电动砂轮机的换挡被4个实验因素所选择，本实验中指定由因素A到因素D（见表1）。每个因素的三个等级（设置）配置包括感兴趣的区域，并定义为数字1，2和3。研磨材料的三种类型，即碳化硅（SIC），白铝氧化物（AL2O3，华盛顿州），粉红色氧化铝（AL2O3，宾夕法尼亚州）分别选用和研究。每个因素三个数值乃根据预先研究结果决定。L18的直交选择由矩阵实验中球形研磨工艺的4个3级因素决定。32数据分析的定义工程设计问题可以划分为较小的较好类型，标准的最佳类型，较大的较好类型，签订目标类型，还有其他的（8）。该信号与信噪比（S/N）比作为目标函数用于优化产品或过程设计。工件表面的表面粗糙度值通过适当的磨削参数组合值应当比原表面的更小。因此，球形研磨过程是一个较小较好类型问题的例子。S/N比，是由以下方程定义8YI在不同条件下，观测噪声质量特性