Effects of honing treatment on AIP-TiN and TiAlN coated end-mill for high speed machining

The objective of this work is to compare the tool performance of TiN and TiAlN coated carbides end-mills deposited by an arc ion plating (AIP) method, using honing treatment to polish the cutting edge surface sleekly. The curve of surface roughness versus honing time showed a rapid improvement initially and thereafter became steady, manifesting a saturation effect. The optimal honing time related to surface roughness was determined to be approximately 20 s. As the surface roughness increased, the critical loads reduced. At an average surface roughness (R_a) of 0.028 (m, the highest critical loads of TiN and TiAlN coating layers were 98 and 114 N, respectively. Tool performances of uncoated and coated tools were conducted under high speed machining (HSM) of AISI D2 cold-worked die steel (62 HRC). Consequently, the TiAlN coated end-mill using honing treatment showed excellent tool life under HSM conditions.     

增韧莫来石陶瓷加工表面的耐磨性分析

本文应用表面粗糙度参数和磨损率，研究增韧莫来石材料磨削，珩磨及平顶珩磨表面的耐磨性能，通过Ra，表面轮廓，支承长度率曲线，轮廓高度幅度分布图，轮廓峰谷比等粗糙度参数评定其加工表面的耐磨性。试验结果表明，增韧莫来石加工表面的磨损率高于原始烧结表面。材料的表面粗糙度影响其耐磨性，材料的磨损率随其表面粗糙度参数Ra值增大而增大，陶瓷表面的耐磨性与加工方式有关，平顶珩磨表面的耐磨性较好。     

镍基高温合金孔珩磨余量对加工质量的影响

针对典型的难加工材料镍基高温合金GH4169开展系统珩磨试验,研究了孔加工表面粗糙度值、圆柱度的变化规律。结果表明:金属结合剂CBN油石珩磨GH4169孔时,随着珩磨进行,表面粗糙度值逐渐下降并趋于稳定,磨粒平均粒度尺寸为100、34和8 μm的油石,所加工的表面能达到的最佳表面粗糙度值R_a分别为0.7、0.3和0.1 μm。基于试验结果,建立了底孔最小加工余量预测模型和最大圆柱度允差预测模型,并进行了试验验证,所建立模型的误差均在10%以内。      

钕铁硼材料的功率超声珩磨加工试验研究

针对钕铁硼材料的高硬度、高脆性的难加工特性,利用功率超声珩磨加工方法,设计了钕铁硼功率超声珩磨加工试验装置,对钕铁硼进行加工试验,通过对试验数据的正交分析,找到了影响钕铁硼加工表面粗糙度和材料去除率的因素,并通过超声振动珩磨与普通珩磨加工钕铁硼材料的表面SEM照片,证明了钕铁硼材料的功率超声珩磨加工相比普通珩磨加工,能够提高钕铁硼材料的加工质量.     

Modeling of material removal rate and surface roughness in finishing of bevel gears by electrochemical honing process

This paper describes mathematical modeling of material removal rate (MRR) and surface roughness of the bevel gears finished by the electro-chemical honing (ECH) process. Since, ECH hybridizes electrochemical dissolution (ECD) and mechanical honing therefore, contribution of ECD in MRR and surface roughness has been modeled using Faraday's law of electrolysis while contribution of mechanical honing has been modeled considering material removal as a phenomenon of uniform wear and using Archard's wear model. Formulations are also proposed for computing the surface area, required by these two models, along the inter-electrode gap (IEG) based on the geometry of the straight bevel gear tooth surfaces. The developed models were experimentally validated using an indigenously developed experimental setup for finishing of bevel gears by ECH based on an envisaged novel concept of twin complementary cathode gears. An aqueous solution containing 25% NaCl + 75% NaNO₃ was used as the electrolyte. The predicted values of MRR and surface roughness have shown close agreement with the experimental values. The experimental results, SEM images and bearing area curve have shown appreciable improvement in the surface roughness and surface integrity ensuring better operating performance of the gears finished by ECH within an optimized finishing time of 2 min.     

超声纵振珩磨表面微观特性的试验研究

在文献[1]中，作者对径向超声振动磨削和纵向（轴向）超声振动珩磨的磨削特点进行了对比研究，建立了磨粒径向超声振动珩磨的切削模型，推导了纵向超声振动珩磨临界速度的计算公式，为了验证所建模型的正确性及进一步研究超声纵振珩磨的磨削表面特征，本文对工程陶瓷ZrO2和高强度P钢进行了纵向超声振动珩磨试验，通过电镜SEM观察分析了表面磨削特征，研究表明：纵向超声振动珩磨具有比普通珩磨较大的材料去除率，并且磨削表面光滑，粗糙度低。     

Macroscopic simulation of the liner honing process

The form quality, the roughness and the surface appearance produced by honing minimizes the friction of the piston in the liner. The process is however mechanically complex and the selection of the process parameters is currently based on empirical methods. The aim of this paper is thus to develop a macroscopic simulation environment of complete real honing cycles, which will help end-users during the setting-up. This virtual tool is based on a space–time discretization and a macroscopic cutting model taking into account local contacts between the workpiece and the abrasive tool. The space–time discretization allows representing the machine environment with the tool, the workpiece and the kinematics. Simulation results are finally validated by comparison with industrial experiments.     

球墨铸铁件软氮化后加工形成的石墨坑对表面质量的影响

介绍了粗糙度的定义,指出球墨铸铁件在软氮化后进行珩磨加工时形成的石墨坑对表面质量的影响,并提出相应的表面质量控制方法。     

Investigation into magnetorheological abrasive honing (MRAH)

A scheme to finish external curved surfaces, by imparting rotation while the abrasive-mixed magnetorheological fluid (or abrasive-mixed MR fluid) is pushed up and down, is presented in this paper. Since the relative motions resemble those present in conventional honing, the proposed method is named as ‘Magnetorheological Abrasive Honing’ (MRAH). This paper outlines the design and development of magnetorheological abrasive honing setup. A DC electromagnet with cylindrical pole faces is used and measurement for magnetic flux density is done. Experiments are conducted with aluminum and austenitic stainless steel workpieces to understand the effect of magnetic field. Effect of initial roughness, workpiece rotation and process duration on finishing was investigated with ground austenitic stainless steel workpieces. It is observed that the improvement in finish is better for rougher surface and higher rotation speed of workpiece and a reduction in roughness is consistent with process duration.     

工程陶瓷发动机缸套零件超声振动磨削研究(Ⅰ)

本文采用作者自行研制的超声振动珩磨机床对工程陶瓷发动机缸套类零件进行了超声振动磨削试验研究。研究表明：对于工程陶瓷（Si3N4、ZrO2、Al2O3）缸体，采用超声振动珩磨，不仅可以取得以团结磨具代替微粉的加工效果，而且可以使工件表面层的微裂纹大幅度减轻；不仅具有比普通珩磨高二倍以上的加工效率，而且具有很高的磨条耐用度（为普通加工下房条耐用度的五倍以上）。对于制造陶瓷发动机缸套类零件来说，本研究提供了一种质量效率兼顾、加工成本较低且可靠性高的加工方法。     

电解研磨扩孔新技术研究

电解研磨扩孔是在吸收电解磨削、电解珩磨和金刚石类磨具研磨等技术优点的基础上开发的一种能浮动定心的高效、低成本的孔后处理加工技术。对该技术的工艺原理、表面粗糙度的影响因素、加工精度及磨具电极的使用寿命等方面进行了研究分析。试验结果和初步应用表明，该技术能有效去除孔加工后的变质层(如再铸层等)，改善表面粗糙度，降低或消除残余应力，提高表面质量。     

直纹回转双曲面--电镀CBN珩磨轮的一种新设计

介绍了CBN珩磨轮的一种新的工艺设计，以一般直纹回转面(单叶双曲面)作为砂轮的给定工作面廓形，对径向珩磨轮的修磨问题及设计方法进行了分析和研究。珩磨轮的刀齿面设计按径向珩齿法进行，采用三种方法刃磨(双曲面法，锥面法和近似法)，并对修磨工艺参数进行了优化。根据齿轮参数，用本方法设计的珩磨轮既可选用径向珩齿法加工鼓形齿，也可用纵向珩齿法加工修缘齿。     

Alternative descriptions of roughness for cylinder liner production

The roughness of stratified surfaces such as cylinder liners, produced by plateau honing, is functionally important in their tribology but is notoriously difficult to characterise. An issue in manufacturing quality control related to their tribological function is the comparative ability of various roughness characterisation systems. In this paper the Rk family of parameters is compared with the Rq family as regards stability and discrimination. When coefficients of variation of the two parameter families are compared as a measure of stability, CVs of individual parameters vary between 8% and 20% but do not seem to indicate a clear advantage to either family. When the correlation of parameters within and between the two groups is computed as a measure of relative discriminative ability, many parameters are found to be highly correlated, to the point where values of Rpk and Rpq are effectively indistinguishable. The relative robustness of the parameters is also established by simulation of surface or measurement artefacts: outlying peaks and valleys, high-frequency noise, changes in stylus or skid radius, changes in high-pass filter and in assessment length. Outlying peaks cause a large increase in Rpk, while outlying valleys have little effect. The Rq parameters are more sensitive to high-frequency noise than the Rk parameters. Increasing the stylus radius reduced the valley parameters, while adding a 25 mm radius skid increased Rk and Rpq by as much as 15%. Increasing the short-wavelength cut-off from 2.5 μm to 8 μm reduced most parameters, particularly the peak parameters, while replacing the robust Gaussian filter used throughout by a valley-suppression filter had little effect. Finally reducing the assessment length from 17 mm to 4 mm decreased the values of many parameters by up to 11%. Increasing plateau honing time decreased plateau roughness, while increasing pressure during coarse honing increased valley roughness, but these changes could not be correlated with roughness parameters. This suggests that the optimum parameter set has not yet been found.     

Roller burnishing of hard turned surfaces

In a hard roller burnishing operation, a hydrostatically borne ceramic ball rolls over the component surface under high pressures. The roughness peaks are flattened and the quality of the workpiece surface is improved. When combined with hard turning, this process provides a manufacturing alternative to grinding and honing operations.The studies determined optimum working parameter ranges. Parameter settings were shown to be non-critical in this process, since constant surface qualities were attainable over wide setting ranges. A second phase of the studies examined the improvements obtained for various original roughnesses. Reductions of 30 to 50 % in mean peak-to-valley height R_z are, for example, achievable, depending on the original roughness.Structure analyses and residual stress measurements were used to examine the effects of the process on the workpiece surface zone. Hard roller burnishing transforms tensile residual stresses present in the surface zone after hard turning into compressive residual stresses. Hard roller burnishing has no effect on the formation of white layers in the surface zone.     

内孔光整可调珩磨头的理论分析与试验研究

目的：目前对内孔的珩磨加工,一种珩磨头只能加工一种口径的内孔,加工尺寸单一,适应性差。为了提高珩磨头的通用性,适应小批量、多规格珩磨加工,介绍一种尺寸可调的珩磨头。方法对珩磨头尺寸调节原理进行了介绍,并分析了珩磨时工件所受的珩磨力以及珩磨头的运动情况。用SolidWorks建立了装置的三维模型,并加工出了适应孔径为95~125 mm的珩磨头实物样机。通过对内径为φ98 mm和φ106 mm的不锈钢钢管进行加工实验,加工6 min后,获取了表面粗糙度Ra变化曲线和加工后的表面形貌。结果加工后φ98 mm管的表面粗糙度Ra值由2.174μm降低到0.869μm,φ106 mm管的表面粗糙度由1.582μm降低到0.758μm。加工后的工件表面变得光滑、明亮,表面形貌得到明显改善。结论珩磨头结构简单易于实现,在普通机床上即可使用,通过实验验证了装置的可行性。     

The 3-D characterisation of the surface topography of the ballizing process

Engineering surfaces are produced by a large number of manufacturing processes and once the processing is complete they are left with a surface texture which reflects the machining operation. Boring, turning, milling, grinding, lapping and honing are typical machining process, whilst roller burnishing and ballizing are typical of processes where improved surface finish as well as modified surface properties are required. These latter two processes, which have been in common usage for many years, have advantages which have not yet been fully explored. This includes the ability to deliberately impart negative residual stresses into the surface which are advantageous in improving the functional life of often stressed components as well as improved surface texture.The main purpose of this paper is to investigate the trends of roughness and residual stress related to the parameters of the ballizing process. This paper uses the 3-D surface evaluation techniques to characterise the ballized (engineered) surface and uses the ring cut-off method to calculate the residual stress on its circumference. This experimental methodology and analysis are used to show that: 1) The wall thickness of the ballized component and the interference amount are significant causes of roughness and residual stress. 2) The speed of the ball (velocity) going through the holes has a little effect on the roughness and residual stress.     

Use of roughness probability parameters to quantify the material removed in plateau-honing

This paper presents a new methodology for quantifying the material to be removed in the finish honing operation of plateau-honing using the roughness probability parameters to obtain a specified surface roughness. An estimated Abbott–Firestone curve is obtained, starting from the specified roughness values, which are defined by the roughness probability parameters: the transition bearing ratio (R_mq), the valley roughness (R_vq) and the plateau roughness (R_pq). To evaluate the accuracy of probability parameters for estimating the Abbott–Firestone curve, a series of cylinders were machined via plateau-honing under different conditions. The difference in area between the experimentally obtained curve and the estimated curve, generated from the measured values of R_mq, R_vq and R_pq, was then calculated. This difference was found to be sufficiently small to enable the use of probability parameters and of the estimated Abbott–Firestone curve. In the experiments performed, different grain sizes were used for the rough strokes (64, 91 and 181 [FEPA standard]), and a grain size of 20 was used for the finishing strokes. The roughness of each cylinder was characterised by measuring roughness at nine different points. The average Abbott–Firestone curve of the nine curves was then determined once the extreme curves had been eliminated according to Chauvenet’s criterion. The Abbott–Firestone curves obtained from the experiments were averaged by using as height reference the heights of Abbott–Firestone profiles corresponding to 92.5%, 95%, 97.5% and 100% of material. The resulting average curve was compared to the estimated Abbott–Firestone curve. The difference in area between the average curve and the estimated curve was calculated. The smallest difference in area between these curves was found for the reference profile height corresponding to 97.5% of the material. This difference was found to be sufficiently small to enable the use of the probability parameters and of the estimated Abbott–Firestone curve. The average differences in area were 9.2% for a rough grain size of 64, 2.1% for a rough grain size of 91 and 2.3% for a rough grain size of 181. The difference in area between the Abbott–Firestone curve corresponding to the rough honing and the estimated Abbott–Firestone curve corresponding to the finish honing is proportional to the quantity of material to be removed in the finishing operation. This methodology will be used as a preliminary step in future work aimed at predicting the parameters that control the process as a function of the specified roughness.     

基于GRNN的珩磨缸套表面3D粗糙度图像检测方法

活塞-缸套系统是内燃机重要的摩擦副之一，活塞-缸套的表面质量影响着活塞-缸套系统的摩擦学性能，进而直接影响整机的服役性能。针对珩磨缸套表面 2D 粗糙度参数的局限性与表面粗糙度非接触检测方法研究，提出一种基于广义回归神经网络(GRNN)的珩磨缸套表面 3D 粗糙度图像检测方法。通过运用灰度共生矩阵(GLCM)提取缸套表面图像的纹理特征参数，并分析纹理特征参数与 3D 粗糙度间的相关性。以图像纹理特征参数作为输入，分别采用 GRNN 和多元回归分析 (MRA)建立 3D 粗糙度检测模型，通过与试验检测结果对比验证了模型的准确性。GRNN 检测模型获得的可决系数 R2均值 (0.962)优于 MRA 检测模型，且均方误差 MSE 均值(0.07)更小，与试验检测结果对比可知，采用 GRNN 建立的珩磨缸套 3D 粗糙度检测模型具有更高的精度，与实测 3D 粗糙度的相对误差均值为 7.9%。所建立的 3D 粗糙度检测模型具有较高的检测精度。     

Development of a honing process for the combination machining of hardened axisymmetric parts

This paper presents a novel concept to enhance the conventional combination machining ‘turning and grinding’ by a long-stroke honing process for finishing bores of axisymetric parts. Honing is the best choice when the surface integrity of tribologically highly-stressed parts is of vital importance. The presented approach reduces the required overall machining time when compared with that of the conventional machining sequence on separate machine tools, and also enhances the production accuracy through a single clamping setup. The fundamental details like tool design, infeed strategies and possible process-chains of the developed approach for honing on a combination machining center are explained. Experimental results of two different process-chains are analyzed: Firstly, the ‘turning-grinding-honing’ (TGH-chain), where honing is conducted after the grinding process; and secondly, the ‘turning-honing’ (TH-chain), where honing is applied directly after the rough turning. The experiments showed promising results for the applied position-controlled infeed strategy of the developed long-stroke honing process regarding the production efficiency.     

缸套珩磨网纹模拟及流动特性分析

目的 研究缸套珩磨网纹表面计算机模拟方法,对比缸套网纹表面确定性分析流量因子与Patir & Cheng高斯分布流量因子差异。方法 采用快速傅里叶变换技术(FFT)及坐标变换,对高斯分布平台表面及具有任意方向的各向异性沟槽表面进行了计算机模拟,并叠加合成满足要求Rpq、Rvq及珩磨角度参数的双高斯缸套珩磨网纹表面。通过表面概率支承率曲线分析,验证该方法的精度。在此基础上,进行给定边界条件下网纹表面的流动分析,对比确定性分析流量因子与Patir & Cheng高斯分布流量因子差异。结果 调整表面高度标准差、珩磨角度及自相关长度,可实现不同参数珩磨网纹的建模,生成的珩磨网纹表面参数与给定输入参数偏差较小。相比Patir & Cheng高斯分布流量因子,珩磨网纹确定性分析压力流量因子能更好地反映珩磨角度对不同方向流量的影响。同时,珩磨网纹沟槽对小间隙下剪切流量的影响更加明显。结论 网纹表面的确定性分析流量因子与Patir & Cheng高斯分布流量因子存在较大差异,缸套网纹表面建模及流动特性分析可更好地反映表面粗糙度对表面润滑性能的影响,为进一步开展缸套-活塞环多尺度摩擦学分析及珩磨网纹参数优化奠定了基础。