金剛石砂輪修整方法大全
1、磨削修整法
1.1磨削(xue)修整法(fa)的原理(li)
修整時是用普通磨料砂輪與金剛石砂輪對磨,金剛石砂輪做旋轉運動,而普通磨料砂輪在做旋轉運動的同時還做進給運動,金剛石砂輪表面的(de)(de)磨粒在摩擦力的(de)(de)作用下開(kai)始(shi)慢(man)(man)慢(man)(man)旋轉(zhuan),旋轉(zhuan)的(de)(de)同時(shi)對金(jin)(jin)屬結合(he)劑(ji)產生一定的(de)(de)擠壓力,至(zhi)使(shi)粘結劑(ji)出(chu)現裂紋,隨著摩擦力的(de)(de)連續作用,造成結合(he)劑(ji)的(de)(de)裂紋進一步擴大,最終粘結劑(ji)破碎(sui),使(shi)磨鈍的(de)(de)金(jin)(jin)剛石顆粒從砂輪表面脫落,鋒利的(de)(de)金(jin)(jin)剛石顆粒顯露出(chu)來從而達到修整(zheng)的(de)(de)目的(de)(de)。
1.2磨削修整法的(de)特點
磨削(xue)修(xiu)(xiu)整(zheng)(zheng)法(fa)的主(zhu)要優點是:結構簡單、操作方便、修(xiu)(xiu)整(zheng)(zheng)時間短(duan)、磨削(xue)速度穩定、磨削(xue)成本(ben)較低(di),但修(xiu)(xiu)整(zheng)(zheng)過程(cheng)存在沖擊力,修(xiu)(xiu)整(zheng)(zheng)效(xiao)率低(di)、修(xiu)(xiu)整(zheng)(zheng)精度差且磨粒脫落較多、整(zheng)(zheng)形(xing)質量(liang)不易控制。多用(yong)于修(xiu)(xiu)整(zheng)(zheng)陶瓷(ci)和樹脂(zhi)粘結劑金(jin)剛石砂輪。
2、軟彈性修整法
2.1軟彈性(xing)修整法的原理(li)
軟彈性修整法在修整時砂帶套在砂帶輪上,修整時金剛石砂輪高(gao)速(su)旋轉(zhuan),卷帶(dai)(dai)輪緩慢轉(zhuan)動(dong),砂帶(dai)(dai)在帶(dai)(dai)輪上慢慢移動(dong),利用砂帶(dai)(dai)與(yu)砂輪的(de)接觸力有效地去除(chu)金剛石砂輪表面磨(mo)粒間的(de)結合(he)劑,從而達(da)到修整的(de)目的(de)。
2.2軟(ruan)彈(dan)性(xing)修整法的優點
與其它修整方法相比,軟彈性修整法更適用于修整金屬結合劑金剛石微粉砂輪,因為金屬結合劑金剛石微粉砂輪既有金屬的塑性,又有很高的硬度,所以修整難度相當大,主要表現在:修整工具表面磨粒很快被磨損,其次是修整工的容屑空間容易堵塞使修整無法繼續。而用軟彈性修整法的修整工具——砂帶總是以新的鋒利磨粒被修整砂輪接觸,能形成良好的修整環境,有效地去除金剛石砂輪(lun)表面磨(mo)粒間的結合(he)劑,且修整時磨(mo)削力較小,磨(mo)削表面質量高。
3、電火花修整法
3.1電火花(hua)修(xiu)整原理(li)
該方法在修整金剛石砂輪過程中,砂輪高速旋轉,金剛石砂輪接電源的正極,工具電極接電源的負極,在金剛石砂輪和工具電極之間噴入磨削冷卻液,電(dian)壓加在工具電(dian)極(ji)與砂(sha)輪之間(jian),火花放電(dian)便在砂(sha)輪金(jin)屬粘(zhan)結劑(ji)與修整電(dian)極(ji)間(jian)產(chan)生,瞬時放電(dian)的高溫使金(jin)屬粘(zhan)結劑(ji)發生氣化(hua),砂(sha)輪表面(mian)的金(jin)屬結合劑(ji)被(bei)有效去(qu)除,金(jin)剛石磨粒被(bei)充分地暴露出來實現對砂(sha)輪的修整。
3.2電火(huo)花修(xiu)整的(de)特點
可實現在線修(xiu)整(zheng),易于保證砂(sha)(sha)輪(lun)的(de)磨削(xue)(xue)精(jing)度(du),修(xiu)整(zheng)后的(de)砂(sha)(sha)輪(lun)磨削(xue)(xue)力小,整(zheng)形(xing)精(jing)度(du)高、且整(zheng)形(xing)和修(xiu)銳可同時完成(cheng),但整(zheng)形(xing)速度(du)較(jiao)慢且電(dian)火花(hua)放(fang)電(dian)修(xiu)整(zheng)金剛石(shi)(shi)砂(sha)(sha)輪(lun)會因為放(fang)電(dian)溫度(du)過(guo)高使(shi)磨粒的(de)性(xing)能發生(sheng)改變,有效控(kong)制砂(sha)(sha)輪(lun)表面的(de)溫度(du)是電(dian)火花(hua)修(xiu)整(zheng)金剛石(shi)(shi)砂(sha)(sha)輪(lun)的(de)關(guan)鍵。
4、激光修整法
4.1激光修整(zheng)法的(de)原理
激光修整法是利用光學系統把激光光束聚焦成很小的光斑作用在砂輪表面,除少部分激光被反射外,絕大部分激(ji)光(guang)被金(jin)屬(shu)粘結劑吸(xi)收,溫(wen)度迅速升(sheng)高(gao),導致被激(ji)光(guang)光(guang)束照射的(de)區(qu)域(yu),金屬粘(zhan)結劑(ji)氣化(hua)而被去除,結合劑(ji)材料(liao)的(de)去除通常經過(guo):照射、吸收、升(sheng)溫(wen)、氣化(hua)幾個(ge)過(guo)程。在激(ji)光(guang)修理砂輪時,合理控制(zhi)激(ji)光(guang)功率及(ji)密度,可以同時去除砂輪表(biao)面(mian)的金(jin)剛石磨粒和結(jie)合劑材料,達到砂(sha)輪整形的目的,通(tong)過(guo)調整激(ji)光加工參(can)數,還可以(yi)選擇性地去除砂輪表(biao)面的結(jie)合劑材(cai)料(liao),使(shi)金剛石磨粒(li)具(ju)有一定的突起高度,達(da)到砂輪(lun)修銳的(de)目的(de)。
4.2激(ji)光修整(zheng)法(fa)的(de)優(you)點(dian)
激光修(xiu)(xiu)整(zheng)(zheng)法是一種(zhong)非接觸修(xiu)(xiu)整(zheng)(zheng)方法,修(xiu)(xiu)整(zheng)(zheng)時(shi)既沒有機械作(zuo)用力、沒有修(xiu)(xiu)整(zheng)(zheng)工(gong)具的損耗(hao),激光作(zuo)用時(shi)間(jian)短,作(zuo)用面積小,對金(jin)剛石(shi)磨粒(li)和粘結劑都沒有損傷(shang),確保(bao)了粒(li)的磨削(xue)性能,且(qie)修(xiu)(xiu)整(zheng)(zheng)效率高,缺點是修(xiu)(xiu)整(zheng)(zheng)工(gong)藝較(jiao)復雜、成(cheng)本較(jiao)高。
5、電解修整法
5.1電(dian)解修(xiu)整法的原理(li)
電解修整法主要用于金屬粘結劑金剛石砂(sha)(sha)(sha)輪(lun),電(dian)(dian)(dian)(dian)(dian)(dian)(dian)解(jie)修(xiu)整(zheng)時,金(jin)(jin)屬結合(he)(he)劑(ji)砂(sha)(sha)(sha)輪(lun)與(yu)直(zhi)流電(dian)(dian)(dian)(dian)(dian)(dian)(dian)源(yuan)正極(ji)(ji)相接(jie)做為(wei)(wei)電(dian)(dian)(dian)(dian)(dian)(dian)(dian)解(jie)陽(yang)極(ji)(ji),工(gong)具(ju)電(dian)(dian)(dian)(dian)(dian)(dian)(dian)極(ji)(ji)與(yu)直(zhi)流電(dian)(dian)(dian)(dian)(dian)(dian)(dian)源(yuan)負極(ji)(ji)相接(jie)做為(wei)(wei)電(dian)(dian)(dian)(dian)(dian)(dian)(dian)解(jie)陰極(ji)(ji),在(zai)陽(yang)極(ji)(ji)和陰極(ji)(ji)之間(jian)(jian)噴入具(ju)有電(dian)(dian)(dian)(dian)(dian)(dian)(dian)解(jie)作用(yong)(yong)(yong)的(de)(de)(de)磨(mo)削液(ye)(ye)(ye)做為(wei)(wei)電(dian)(dian)(dian)(dian)(dian)(dian)(dian)解(jie)液(ye)(ye)(ye),使(shi)金(jin)(jin)剛石(shi)砂(sha)(sha)(sha)輪(lun)、電(dian)(dian)(dian)(dian)(dian)(dian)(dian)解(jie)液(ye)(ye)(ye)、工(gong)具(ju)電(dian)(dian)(dian)(dian)(dian)(dian)(dian)極(ji)(ji)和電(dian)(dian)(dian)(dian)(dian)(dian)(dian)源(yuan)構成(cheng)電(dian)(dian)(dian)(dian)(dian)(dian)(dian)解(jie)回路,修(xiu)整(zheng)時,讓電(dian)(dian)(dian)(dian)(dian)(dian)(dian)解(jie)液(ye)(ye)(ye)充滿陰極(ji)(ji)與(yu)陽(yang)極(ji)(ji)之間(jian)(jian)的(de)(de)(de)間(jian)(jian)隙,電(dian)(dian)(dian)(dian)(dian)(dian)(dian)流從砂(sha)(sha)(sha)輪(lun)經電(dian)(dian)(dian)(dian)(dian)(dian)(dian)解(jie)液(ye)(ye)(ye)流向修(xiu)整(zheng)砂(sha)(sha)(sha)輪(lun),金(jin)(jin)剛石(shi)砂(sha)(sha)(sha)輪(lun)表面的(de)(de)(de)金(jin)(jin)屬結合(he)(he)劑(ji)的(de)(de)(de)金(jin)(jin)屬成(cheng)份在(zai)電(dian)(dian)(dian)(dian)(dian)(dian)(dian)解(jie)液(ye)(ye)(ye)作用(yong)(yong)(yong)下,溶于電(dian)(dian)(dian)(dian)(dian)(dian)(dian)解(jie)液(ye)(ye)(ye)中(zhong),并(bing)與(yu)電(dian)(dian)(dian)(dian)(dian)(dian)(dian)解(jie)液(ye)(ye)(ye)中(zhong)的(de)(de)(de)氫氧根離子化合(he)(he),生成(cheng)微小固體被(bei)流動的(de)(de)(de)電(dian)(dian)(dian)(dian)(dian)(dian)(dian)解(jie)液(ye)(ye)(ye)帶走,大大降低了金(jin)(jin)剛石(shi)砂(sha)(sha)(sha)輪(lun)表層(ceng)粘結強(qiang)度,這個時候再使(shi)用(yong)(yong)(yong)機械(xie)修(xiu)整(zheng)法,修(xiu)整(zheng)性能就可以得到了極(ji)(ji)大的(de)(de)(de)改(gai)善。所以電(dian)(dian)(dian)(dian)(dian)(dian)(dian)解(jie)修(xiu)整(zheng)是以電(dian)(dian)(dian)(dian)(dian)(dian)(dian)化學(xue)作用(yong)(yong)(yong)為(wei)(wei)主(zhu),機械(xie)作用(yong)(yong)(yong)為(wei)(wei)輔進行的(de)(de)(de)一種復合(he)(he)修(xiu)整(zheng)方(fang)法。
5.2電解修整法(fa)的(de)特點
電解(jie)修(xiu)(xiu)整(zheng)法(fa)可(ke)以(yi)方(fang)便的(de)實現金(jin)屬(shu)結合劑金(jin)剛石砂輪(lun)(lun)在線(xian)電解(jie)修(xiu)(xiu)整(zheng),且整(zheng)形與修(xiu)(xiu)銳(rui)可(ke)同時完(wan)成(cheng),容易控制金(jin)剛石砂輪(lun)(lun)表面的(de)切削狀態(tai),用電解(jie)法(fa)修(xiu)(xiu)整(zheng)金(jin)剛石砂輪(lun)(lun)的(de)優點(dian)是修(xiu)(xiu)整(zheng)時間(jian)短、磨削熱小(xiao),避免了金(jin)剛石砂輪(lun)(lun)因(yin)修(xiu)(xiu)整(zheng)溫度(du)過(guo)高(gao)磨粒碳化導致砂輪(lun)(lun)壽命下降,缺點(dian)是電解(jie)修(xiu)(xiu)整(zheng)法(fa)整(zheng)形精度(du)不高(gao),修(xiu)(xiu)整(zheng)成(cheng)本較大,工藝較復(fu)雜。
6、結束語
金剛(gang)(gang)石(shi)砂輪的(de)修整(zheng)(zheng)(zheng)(zheng)是實(shi)現硬脆材(cai)料的(de)精(jing)密(mi)磨(mo)(mo)削(xue)、超(chao)精(jing)密(mi)磨(mo)(mo)削(xue)、高效(xiao)(xiao)(xiao)磨(mo)(mo)削(xue)、成形磨(mo)(mo)削(xue)的(de)關鍵。金剛(gang)(gang)石(shi)砂輪的(de)修整(zheng)(zheng)(zheng)(zheng)方法種(zhong)類繁多,各具特色,本文只(zhi)介紹(shao)了(le)目前研究應(ying)用較廣、修整(zheng)(zheng)(zheng)(zheng)效(xiao)(xiao)(xiao)果較好(hao)的(de)幾(ji)種(zhong)修整(zheng)(zheng)(zheng)(zheng)方法,在實(shi)際應(ying)用中還要綜合考慮工(gong)件、加工(gong)等各方面因(yin)素,選擇最優修整(zheng)(zheng)(zheng)(zheng)方案,以達到最佳的(de)修整(zheng)(zheng)(zheng)(zheng)效(xiao)(xiao)(xiao)果。