电火花修整超硬磨料砂轮技术发展现状

摘要/Abstract

摘要：

电火花加工技术的发展带动了电火花修整超硬磨料砂轮技术，改变了传统砂轮“硬接触”修整方法。近年来，许多学者致力于研究超硬磨料砂轮的电火花修整方法，为提高磨削效率和磨削精度做了大量有意义的研究。基于大量文献的论述与研究，回顾了近三十年来电火花修整超硬磨料砂轮技术发展过程的各种研究内容以及取得的成果，完整地阐述了电火花修整金属基超硬磨料砂轮技术的基本原理。以立方氮化硼(CBN)和金刚石磨料砂轮修整为主要应用，对不同电极、不同放电介质、不同放电参数以及现代工程理论辅助下的建模分析方法等方面做了介绍，分析了现有电火花修整技术发展中存在的问题，探讨了未来发展的方向及趋势。

关键词: 电火花修整, 金属结合剂, 超硬磨料砂轮, 发展现状

Abstract:

EDD of superabrasive grinding wheel was developing with electrical discharge machining (EDM) technology, changing the traditional wheel dressing methods based on hard contact. In recent years, many researchers were working on EDM dressing methods of superabrasive grinding wheel and achieving a lot of significant results to contribute to the efficiency and precision grinding. Based on numerous literatures, the research fruits on the development of EDD technology within the last thirty years were reviewed. The basic principles of EDM dressing technology of metal-bonded superabrasive grinding wheel were introduced. According to the dressing applications of CBN and diamond grinding wheels, the effects of different electrodes, different dielectrics, different electrical parameters and modeling with modern design theories were presented. The existing problems in the developing EDD technology were analyzed, and the future developing directions were also discussed.

Key words: electrical discharge dressing(EDD), metal-bonded;superabrasive grinding wheel, development state

中图分类号:

TG661
TG580

余剑武, 何利华, 黄帅, 尚振涛, 吴耀, 段文. 电火花修整超硬磨料砂轮技术发展现状[J]. 中国机械工程, 2015, 26(16): 2254-2262.

Yu Jianwu, He Lihua, Huang Shuai, Shang Zhentao, Wu Yao, Duan Wen. State-of-the-Art of Electrical Discharge Dressing Technology for Superabrasive Grinding Wheel[J]. China Mechanical Engineering, 2015, 26(16): 2254-2262.

参考文献

[1]郭东明,刘战强,蔡光起,等. 中国先进加工制造工艺与装备技术中的关键科学问题[J]. 数字制造科学, 2005, 3(4)：1-36.
Guo Dongming,Liu Zhanqiang,Cai Guangqi, et al.Crucial Technical Problems in China’s Advanced machining, Manufacturing and Relevant Equipment Technologies[J]. Manufacture Science, 2005, 3(4)：1-36.
[2]雷源忠,黎明. 关于发展先进制造技术基础性研究的策略构想[J]. 中国科学基金, 1996(1)：27-30.
Lei Yuanzhong,Li Ming.Strategy for the Basic Research on Developing Adcanced Manufacturing Technology[J]. Bulletin of National Science Foundation of China, 1996(1)：27-30.
[3]Saleh T, Rahman M S, Lim H S, et al. Development and Performance Evaluation of an Ultraprecision ELID Grinding Machine[J]. Materials Processing Technology, 2007, 192-193：287-291.
[4]胡德金, 蔡兰蓉, 贾妍. 超硬磨料砂轮电加工修整技术及其最新进展[C]// 2007年中国机械工程学会年会之第12届全国特种加工学术会议论文集.长沙：中国机械工程学会特种加工分会, 2007:142-146.
[5]Tonshoff H K, Karpuschewski B, Mandrysc T, et al. Grinding Process Achievements and Their Consequences on Machine Tools Challenges and Opportunities[J]. CIRP Annals-Manufacturing Technology, 1998, 47(2)：651- 668.
[6]陈根余,谢小柱, 李力钧,等. 超硬磨料砂轮修整与激光修整新进展[J]. 金刚石与磨料磨具工程, 2002(2)：8-12.
Chen Genyu, Xie Xiaozhu, Li Lijun, et al.Superabra- sive Grinding Wheel Dressing and Laser Truing Progress[J]. Diamond & Abrasives Engineering, 2002(2)：8-12.
[7]今井祥人. 电火花加工——学以致用[M].郭常宁,译.北京：机械工业出版社, 2012.
[8]刘志东. 特种加工[M]. 北京：北京大学出版社, 2013.
[9]Tsai H C, Yan B H, Huang F Y. EDM Performance of Cr/Cu-based Composite Electrodes[J]. Int. J. of Machine Tools and Manufacture, 2003, 43(3):245-252.
[10]Kalpajians S, Schmidsr S R. Manufacturing Processed for Engineering Materials[M]. 4th ed. New Jersey：Prentice Hall, 2003.
[11]Suzuki K,Uematsu T,Nakagawa T.On-machine Trueing/Dressing of Metal Bond Grindingwheels by Electro-discharge Machining[J]. CIRP Annals-Manufacturing Technology, 1987, 36(1)：115-118.
[12]Chen D Z, Tian Y Y. Form Dressing of Metal-bonded Diamond Wheel[C]//Proceedings of the International Symposium on Electro-machining (ISEM) IX. Nagoya：Japan Society of Electrical-Machining Engineers, 1989:18-21.
[13]Kim J D, Lee E S, Lee C Y. Crack Generation and the Effect of In-process Electro-discharge Dressing in Grinding Single Crystal MgO[J]. International Journal of Mechanical Sciences, 1995,37(6)：569-583.
[14]Mohri N, Saito N, Higashi M, et al. A New Process of Finish Machining on Free Surface by EDM Methods[J]. CIRP Annals-Manufacturing Technology, 1991,40(1)：207-210.
[15]Lee E S, Ahn S O. Precision Surface Grinding of Mn-Zn Ferrite with In-process Electro-discharge Dressing (IEDD)[J]. International Journal of Machine Tools & Manufacture, 1999,39(10)：1655-1671.
[16]黄兆祥,熊天渝,王世民. 电火花放电能量测量及放电过程分析[J]. 工程热物理学报, 1982, 3(4)：394-399.
Huang Zhaoxiang,Xiong Tianyu, Wang Shiming.Spark Energy Measuring Technology and Performance Analysis of Spark Discharge Process for Electric Spark Ignition[J]. Journal of Engineering Thermophysics, 1982, 3(4)：394-399.
[17]Marin G, Pavel K, Milenko S, et al. Influence of Discharge Energy on Machining Characteristics in EDM[J]. Journal of Mechanical Science and Technology, 2012,26(1)：173-179.
[18]Shao J, Zhang Y Q. Study on the Positive EDM Based on the Field Emission Theory[J]. Applied Mechanics and Materials, 2014, 494/495：424-427.
[19]Wang X K, Ying B G, Liu W G. EDM Dressing of Fine Grain Super Abrasive Grinding Wheel[J]. Journal of Materials Processing Technology, 1996,62(4)：299-302.
[20]Sanchez J A, Ortega N, Lopez D L N, et al. Analysis of the Electro Discharge Dressing (EDD) Process of Large-grit Size CBN Grinding Wheels[J]. Advanced Manufacturing Technology, 2006,29(7/8)：688-694.
[21]Lee E S. Surface Characteristics in the Precision Grinding of Mn-Zn Ferrite with In-process Electro-discharge Dressing[J]. Journal of Materials Processing Technology, 2000,104(3)：215-225.
[22]王先逵, 应宝阁, 刘为刚,等. 金属结合剂金刚石砂轮的电火花整形[J]. 航空精密制造技术, 1995(2)：19-23.
Wang Xiankui,Ying Baoge,Liu Weigang, et al.Microscopic Study of EDM Dressing for Diamond Powder Grinding Wheel[J]. Aviation Precision Manufacturing Technology,1995(2)：19-23.
[23]Sancheza J A, Pombo I, Cabanes I, et al. Electrical Discharge Truing of Metal-bonded CBN Wheelsusing Single-point Electrode[J]. International Journal of Machine Tools & Manufacture, 2008,48(3/4)：362-370.
[24]王艳, 邓琦林, 胡德金,等. 金刚石砂轮修整新技术的研究[J]. 电加工与模具, 2003(5)：1-5.
Wang Yan,Deng Qilin,Hu Dejin, et al.Study on New Technology of Diamond Wheel Dressing[J]. Electro- machining & Mould,2003(5)：1-5.
[25]Cai L R, Li M, Yang H, et al. Electrical Discharge Dressing Metal-bonded Diamond Grinding Wheels with Various Mediums[J]. Journal of Engineering Manufacture, 2013,227(1)：102-108.
[26]洪建军, 蔡兰蓉, 胡德金. 不同介质中电火花修整金属基金刚石砂轮的研究[J]. 电加工与模具, 2008(6)：27-30.
Hong Jianjun,Cai Lanrong,Hu Dejin.An Experimental Compare on Discharge Mediums Used for Electrical Discharge Machining(EDM) of Metal-bonded Diamond Grinding Wheel[J]. Electromachining & Mould,2008(6)：27-30.
[27]Xie J, Tamaki J. An Experimental Study on Discharge Mediums Used for Electro-contact Discharge Dressing of Metal-bonded Diamond Grinding Wheel[J]. Journal of Materials Processing Technology, 2008,208(1/3)：239-244.
[28]Xu M M, Li D D, Hu D J, et al. Laminated Manufacturing and Milling Electrical Discharge Dressing of Metal-bonded Diamond Grinding Wheels[J]. Journal of Engineering Manufacture, 2012,226(B1)：137-144.
[29]Weingartner E, Roth R, Kuster F, et al. Electrical Discharge Dressing and Its Influence on Metal Bonded Diamond Wheels[J]. CIRP Annals-Manufacturing Technology, 2012,61(1)：183-186.
[30]Wang Y, Zhou X J, Hu D J. An Experimental Investigation of Dry-electrical Discharge Assistedtruing and Dressing of Metal Bonded Diamond Wheel[J]. Int. Journal of Machine Tools & Manufacture, 2006,46(3/4)：333-342.
[31]Hashimoto F, Kanai A. High Precision Trueing Method of Regulating Wheel and Effect on Grinding Accuracy[J]. CIRP Annals-Manufacturing Technology, 1983,32(1)：237-239.
[32]张丙鹏, 赵文祥, 王西彬,等. 金刚石微粉烧结棒和D、GC杯型砂轮修整碟型金刚石砂轮对比研究[J]. 金刚石与磨料磨具工程, 2005(5)：13-17.
Zhang Bingpeng, Zhao Wenxiang, Wang Xibin, et al.Dressing Diamond Dish Wheel with Diamond Powder Sinteredbar and wtih D Cup Wheel+GC Cup Wheel[J]. Diamond & Abrasives Engineering,2005(5)：13-17.
[33]李继贤, 张飞虎. 成形砂轮修整技术研究现状[J]. 机械工程师, 2006(10)：19-22.
Li Jixian, Zhang Feihu.Research Situation of the Forming Wheel Dressing Technology[J]. Mechanical Engineer,2006(10)：19-22.
[34]Lavine A S, Malkin S, Jen T C. Thermal Aspects of Grinding with CBN Wheels[J]. CIRP Annals-Manufacturing Technology, 1989, 38(1)：557-560.
[35]Ohmori H, Li W, Makinouchi A, et al. Efficient and Precision Grinding of Small Hard and Brittlecylindrical Parts by the Centerless Grinding Processcombined with Electro-discharge Truing Andelectrolytic In-process Dressing[J]. Journal of Materials Processing Technology, 2000,98(3)：322-327.
[36]Ortega N, Sanchez J A, Aranceta J, et al. Optimisation of Grit Protrusion in the Electro-discharge Dressingprocess of Large Grit Size CBN Grinding Wheels[J]. Journal of Materials Processing Technology, 2004,149(1/3)：524-529.
[37]王先逵, 应宝阁, 刘为刚. 金刚石微粉砂轮电火花修锐微观研究[J]. 制造技术与机床, 1995(12)：13-16.
Wang Xiankui,Ying Baoge,Liu Weigang.Micro- scopic Study of EDM Dressing for Diamond Powder Grinding Wheel[J]. Manufacturing Technology&Machine Tool,1995(12)：13-16.
[38]Zhang C, Hitoshi O, Li W. Precision Shaping of Small Diameter Wheels Using Microelectric Discharge Truing (MEDT) and Hole-machining of Al2O3 Material[J]. International Journal of Machine Tools & Manufacture, 2000,40(5)：661-674.
[39]Lee E S. Surface Characteristics in the Precision Grinding of Mn-Zn Ferrite with In-process Electro-discharge Dressing[J]. Journal of Materials Processing Technology, 2000,104(3)：215-225.
[40]Chen M J, Li Z A, Yu B, et al. On-machine Precision Preparation and Dressing of Ball-headed Diamond Wheel for the Grinding of Fused Silica[J]. Chinese Journal of Mechanical Engineering, 2013, 26(5)：982-987.
[41]Konig W, Dauw D F, Levy G, et al. EDM-future Steps towards the Machining of Ceramics[J]. CIRP Annals-Manufacturing Technology, 1988, 37(2)：623-631.
[42]许明明, 李冬冬, 胡德金. 空气介质中非金属基金刚石砂轮的修整效果[J]. 上海交通大学学报, 2011, 45(6)：907-910.
Xu Mingming, Li Dongdong, Hu Dejin.Effect on Truing and Dressing Non-mental Bond Diamond Grinding Wheel in Air[J]. Journal of Shanghai Jiaotong University,2011, 45(6)：907-910.
[43]Xu M M, Li D D, Hu D J, et al. Mist-jetting Electrical Discharge Dressing (MEDD) of Nonmetal Bond Diamond Grinding Wheelsusing Conductive Coating[J]. Int. Journal of Advanced Manufacturing Technology, 2012,63(9/12)：955-961.
[44]Iwai M, Ninomiya S, Ueda T, et al. Electrical Discharge Truing of a Vitrified Bonded Superabrasive Wheel with Electrical Conductivity[C]//International Conference on Manufacturing Engineering and Automation (ICMEA 2012). Zurich:Trans. Tech. Publications Ltd., 2012:591-593.
[45]Lok Y K, Lee T C. Processing of Advanced Ceramics Using the Wire-cut EDM Process[J]. Journal of Materials Processing Technology, 1997,63(1/3)：839-843.
[46]Rhoney B K, Shih A J, Scattergood R O, et al. Wire Electrical Discharge Machining of Metal Bond Diamond Wheels for Ceramic Grinding[J]. International Journal of Machine Tools & Manufacture, 2002,42(12)：1355-1362.
[47]Rhoney B K, Shih A J, Scattergood R O, et al. Wear Mechanism of Metal Bond Diamond Wheels Trued by Wire Electrical Discharge Machining[J]. Wear, 2002,252(7/8)：644-653.
[48]Konrad W, Eduardo W, Marc B. In-process Wire Electrical Discharge Dressing (IWEDD) of Metal Bonded Diamond Wheels[J]. CIRP Annals-Manufacturing Technology, 2013, 62(1)：339-342.
[49]Tamaki J, Kondoh K, Iyama T. Electrocontact Discharge Dressing of Metal Bonded Diamond Grinding Wheel Using a Hybrid Electrode[J]. Journal of the Japan Society for Precision Engineering, 1999, 65(11)：1628-1632.
[50]Xie J, Tamaki J. In-process Evaluation of Grit Protrusion Feature for Fine Diamond Grindingwheel by Means of Electro-contact Discharge Dressing[J]. Journal of Materials Processing Technology, 2006,180(1/3)：83-90.
[51]Lu Y J, Xie J, Wu K K, et al. Experimental Study on Dry Electrical Contact Discharge (ECD) Dressing Parameters of Coarse Diamond Grinding Wheel[C]//16th International Symposium on Advances in Abrasive Technology.Zurich:Trans. Tech. Publications Ltd., 2013:746-750.