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ОСОБЕННОСТИ РАЗРАБОТКИ НОВЫХ УСТРОЙСТВ НА ОСНОВЕ НАНОСТРУКТУРИРОВАННЫХ МАТЕРИАЛОВ
PECULIARITIES OF THE DEVELOPMENT
OF DEVICES BASED ON NANOSTRUCTURED MATERIALS
05.02.00 - МАШИНОСТРОЕНИЕ И МАШИНОВЕДЕНИЕ
MECHANICAL ENGINEERING
05.02.08 - ТЕХНОЛОГИЯ МАШИНОСТРОЕНИЯ
(ТЕХНИЧЕСКИЕ НАУКИ) ENGINEERING TECHNOLOGY
DOI: 10.33693/2313-223X-2020-7-3-23-28
Kinematic features of the lapping process and determination of its basic parameters
Eziz Sarvan Shirvan ©
War College of the Armed Forces of the Ministry of Defense of the Republic of Azerbaijan, Baku, Republic of Azerbaijan
E-mail: [email protected]
Abstract. This paper discusses the kinematic characteristics of lapping process and the main parameters of the process. It was determined that the influencing degree of technological parameters to the forming surface and processes. It was projected the construction of the lapping head for processing of internal cylindrical surfaces, scheme of the lapping operation and graphic description of the forces influencing. The relationships between the axial, radial and tangential cutting forces and the effect of the combined force thereof are determined in order to ensure the necessary surface pressure. During the analysis geometric and mathematical relationships were obtained. The extracted analytical expressions can be realized by further experimental researches and can be used in engineering calculations of technological parameters of processing by lapping. Angular velocity, friction force, linear velocity, also the length of the tactile curve and the radius of the part can be considered the main kinematic and dynamic parameters of the process that the formation of the surface, also the course of the process depends on these parameters. Depending on the kinematic parameters, the wear nature of the tool changes and this changes the linear and angular velocities, which have a significant impact on the accuracy, quality and productivity of processing. When examining the technological capabilities of the process, the nature of the movement between the part and the grinding tool, also changes in cutting speed are often considered as a main factor. Analytical expressions were obtained to determine the main parameters of the process, taking into account the kinematic characteristics of the friction process. These expressions can be used in engineering calculations and allow to determine the optimal values of the processing mode. In order to obtain the required micrometric surface cleanliness and measurement accuracy, correlation relationships were established between the main parameters of the process, equations of the equilibrium system of shear forces were compiled and analytical expressions were obtained based on the analysis of kinematic and dynamic properties of the system.
Key words: abrasive sand, lapping, friction coefficient, kinematic characteristics, shear force
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FOR CITATION: Eziz Sarvan Shirvan. Kinematic features of the lapping process and determination of its basic parameters. Computationalnanotechnology. 2020. Vol. 7. No. 3. Pp. 23-28. DOI: 10.33693/2313-223X-2020-7-3-23-28
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ОСОБЕННОСТИ РАЗРАБОТКИ НОВЫХ УСТРОЙСТВ НА ОСНОВЕ НАНОСТРУКТУРИРОВАННЫХ МАТЕРИАЛОВ PECULIARITIES OF THE DEVELOPMENT OF DEVICES BASED ON NANOSTRUCTURED MATERIALS
DOI: 10.33693/2313-223X-2020-7-3-23-28
Кинематические особенности процесса притирки и определение его основных параметров
Азиз Сарван Ширван оглу ©
Военная Академия Вооруженных сил Азербайджанской Республики, г. Баку, Республики Азербайджан
E-mail: [email protected]
Аннотация. В статье изучены кинематические особенности и основные параметры процесса притирки. Определены влияния технологических параметров на формирование поверхностей и на процесс обработки. Для обработки внутренних цилиндрических поверхностей проектирована новая конструкция притирочной головки и показаны графические схемы операций и процесса действующих сил. Для обеспечения нужного давления на поверхность - определены отношения между, осевыми, радиальными и тангенциальными силами резания и воздействия их суммарной сил. Во время кинематического анализа получены геометрические и математические соотношения. Выделенные аналитические выражения могут быть реализованы путем дальнейших экспериментальных исследований и с помощью притирки могут быть использованы в инженерных расчетах технологических параметров процесса переработки. Основные кинематические и динамические параметры процесса включают в себя - угловую скорость, силу трения, линейную скорость, а также линию соприкосновения к кривой и радиус детали. Ход процесса существенно зависит от этих показателей. В зависимости от кинематических параметров, характер износа притирочной головки варьирует, в связи с чем происходит изменения линейной и угловой скорости влияющих на точность, качество и производительность обработки. В большинстве случаев при изучении технологических возможностей процесса характер движения между деталью и смазочным инструментом, а также изменения скорости резания принимаются за основной фактор. Для определения основных параметров процесса притирки с учетом кинематических характеристик обработки вводятся аналитические выражения. Эти выражения используются в инженерных расчетах и позволяют устанавливать оптимальные значения режимов обработки. Для получения требуемой микрометрической чистоты поверхности и точности измерений устанавливаются корреляционные связи между основными параметрами процесса, составляются уравнения равновесия режущих сил и получают аналитические выражения с помощью анализ кинематических и динамических свойств системы.
Ключевые слова: абразивные зерно, процесса притирки, коэффициент трения, кинематические характеристики, силы резания
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ССЫЛКА НА СТАТЬЮ: Азиз Сарван Ширван оглу. Кинематические особенности процесса притирки и определение его основных параметров // Computational nanotechnology. 2020. Т. 7. № 3. С. 23-28. DOI: 10.33693/2313-223X-2020-7-3-23-28
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INTRODUCTION
Numerous studies have shown that machines of completely identical designs often have very different robustness. This differs in the technological processes of their manufacture. The latter circumstance leads to the need to control the operation of the operating parameters of machines with the help of technological methods. This operating system shows itself most clearly when machining high-precision machine parts. The general characteristics of high-precision parts show that the tolerances for their manufacture are calculated in micrometers. In many cases, the processing errors of the process used are commensurate with or exceed the tolerances. The study of the phenomena occurring in the studied processes can contribute to improving the reliability of real parts, since these patterns can establish the causes of the phenomena and the conditions for regulating the parameters of technological processes, as a result of which the operational properties of the machine parts are formed. Thus, the study of phenomena and technological laws can allow more fully and reliably present the overall picture of the process
of formation of final characteristics of the quality of the treated surfaces, significantly improve the process of processing and achieve the required quality of surface, providing enhanced reliability and long life of parts of machines and mechanisms [11; 12].
Improving the technological operations of finishing processing, introducing new progressive methods of final processes, allows us to provide the necessary high accuracy and quality of the processed surfaces of machine parts. Increasing requirements for durability, stability, anti-corrosion resistance of parts, as well as to improve the accuracy of the machines and mechanisms, their reliability and durability necessitates the use of advanced processing methods. One of which is the technological process of lapping. Lapping refers to finishing processes with a free abrasive. Studying the phenomena occurring during fine abrasive machining, which is lapping, development of advanced production technologies for lap, automating their production, development and widespread use in the industry of diamonds and other super hard materials, the study of the influence of process parameters on the formation of surface quality and on the operational
Eziz Sarvan Shirvan
properties of parts, the increase in their durability is an urgent task before mechanical engineering.
The lapping process is a mutual cutting of the lapping and details of the abrasive grains carved in them. A grain tied to the surface is a grain having two or more contact layers tied to the surface layers of the part and the lapping tool. When processing a part, the grain carries out the cutting process, resting on the surface of the lap. However, it may be removed from this surface if its resistance to cutting force is insufficient.
Grain suspended between the surfaces of the part and ground lapping, as well as grain protruding from the ground surface and not in contact with the work piece surface, cannot carry out the cutting process. Therefore, the grain protruding from the surface of the lapping and lapping the surface of the part presses on them with a certain force and the cutting process occurs due to the cutting force depending on this occurring in the cutting zone - scratching.
THEORETICAL MODELING
The difficulty of solving the problem of investigating the lapping process with the dosing of the material of the surface layer lies in the fact that surface treatment occurs with a free abrasive and under the influence of a large number of functional and random factors. One of which is the diversity of geometric shapes of cutting grains, which have an additional free movement and change their position during processing, which complicates the study of the interaction of cutting grains with the surface to be processed, as well as the influence various technological parameters of the quality of the surface and accuracy of processing [1; 4].
The study of the technological method of lapping with a dosed removal of the material of the surface layer makes it possible to establish its stable scheme, which serves as a basis for predicting the quality of the surface, the accuracy of processing, the production, the choice of optimal process conditions and other.
The lapping of parts, as a technological process, is carried out with the purpose of forming the surfaces of parts with a given accuracy and dimensions and obtaining the required quality of the surface layer. When lapping in, the process has the same process factors and the same physical phenomena are observed as in the abrasive wear of the surfaces of the machine parts in the process of their operation. The main issues of abrasive destruction of solids are: the study and determination of the most probable scheme of the force interaction of free and fixed abrasive grains with material of part, the study of the impacted state of the material in the zone of interaction of the grain with the deteriorating body, the nature of the destruction of the interaction of the active bodies of the part-abrasive-grounding system at given conditions and processing modes [8; 9].
Usually, with finishing operations, including during lapping, practical interest is the determination of the accuracy of the shape of the surfaces of parts depending on the working surface of the lap, taking into account the specified kinematic mode of processing. In the system under study (detail-abrasive layer-lapping), the inaccuracy of the condition of the part before lapping-in causes a redistribution of pressure along the wearing surfaces of the work piece and the lapping-in. The main reason for the redistribution of pressure is the wear of bodies [6; 13]. Analyzing the physic-mechanical phenomena and some of the patterns occurring in the lapping, we can conclude that the process of forming the surfaces of the parts is mainly carried
out when correcting the errors of the workpiece and partial transfer to the next stage of processing.
The intensity of the action of the above factors directly depends on the pattern of movement of the workpiece and lap, the uneven distribution of abrasive over the contact of the workpiece with the lap, the pressure distribution in the metal removal zone, the effect of cutting forces, etc.
In connection with the foregoing, this section of the work is devoted to the influence of the main parameters of the lapping process on the cutting forces, in order to optimize these parameters in relation to providing machining with the lowest possible small cutting forces, as well as the analysis of the technological capabilities of the lapping process to achieve the accuracy of the surfaces of the machine parts in the machining process [3; 15].
The purpose of this work is to improve the quality and accuracy of the machined surfaces of machine parts, by improving the lapping and complex study of its technological capabilities.
To achieve this goal it is necessary to solve the following main tasks.
1. To carry out the kinematic and dynamic analysis of the lapping process taking into account its main parameters.
2. Investigate the components of the cutting force, depending on the basic parameters of the lapping process. Optimize these parameters to ensure machining with the lowest possible cutting forces. Analyze the patterns of the formation of precision measurements of internal cylindrical surfaces, processed by lapping.
3. Investigate the surface roughness depending on the elements of the cutting mode and other parameters of the lapping process. To optimize these elements and parameters in relation to ensuring the minimum roughness of the processed surfaces.
4. Investigate the nature and distribution of residual stresses and work hardening in the surface layer in order to ensure that these properties can be controlled by adjusting the basic parameters of lapping. Investigate the mechanism for the manifestation of technological heredity in terms of surface quality and accuracy of processing in the process of lapping.
5. Develop instrumental adjustments and lapping technology when machining high-precision non-rigid thin-walled parts, carry out their industrial tests and give recommendations for their industrial implementation.
The kinematic parameters of the lapping process, to which the angular velocity Vd, the length of the contact arc the radius of the part R and others, should be taken, significantly influence the shape of the surfaces during processing.
Depending on the characteristics of the processing method and lapping, the sizes of the lubrication head is determined approximately and it is given rotating and forward-back -combined working movement in respect of the processed surface [5; 7]. These movements influence directly the intensity and removal characteristics of the metal layer, creates spiral crossing lines on the surface so that influence the durability of the detail according to the exploitation condition.
Analysis of the kinematic scheme of the lapping process shows that the cutting process is characterized by the combined actions of the axial Px, the radial Py and the tangential Pz components of the cutting force (Fig. 1). According to Fig. 1, each of these forces is directed along the respective three directions O , O and O .
X' y z
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PECULIARITIES OF THE DEVELOPMENT OF DEVICES BASED ON NANOSTRUCTURED MATERIALS
Principal scheme of the lubrication head for the processing of eth internal cylindrical surfaces is shown in Fig. 1, here 1 - processed detail, 2 - lubrication, 3 - bow. External bows maintain the completeness of the lapping tool by creating always the force forwards to the centre from the external surface of the lubrication, internal bows press the lapping tool into the internal surface of the detail and are assigned to provide the pressure to the processed surface. The lubrication head does both forward-back and rotating movements.
It is described the different conditions of the lapping process in Fig. 2. According to the scheme, radial dislocation of the lubrication elements equals to (1/2)5.. Then, it can be expressed as following according to the lapping scheme:
sin ф. = S./2r, or S. = 2r sin ф.,
(5)
here r - changed radiuses depending on the abrasion of external surface fo the lubrication, mm; - dislocation angle of the elastic lubrication elements during the abrasion, rad.
I
Fig. 1. Schematic description of the forces pressuring to the lapping process:
1 - detail; 2 - lubrication; 3 - bows
Fig. 2. Different conditions of the lapping process
Compile up the equations of the balance system of the shear forces occurred during the processing with lapping:
P + F - P.
-0;
Py + Q - N - Pn = 0;
(1)
here Px- axial cutting force N; F - friction force occurred in teh forwar-back movement of the lubrication N; P - axial force N; P -
'ox y
radial shear force N; Q - sum of the forces occurred by the bows directed from the detail centre N; N - sum of the forces occurred by the bows directed to the detail centre N; Pn - normal reaction force N; Pz - is the tangential component of the cutting force N; Fd - force characterizing the rotating movement of the detail N; F - friction force occurred in the rotating movement of the lubrication N; Friction force occurred in the forward-back movement of the lubrication (F ) is determined by the following expression:
Fs, = t x,
(2)
Si r- x, t
here | - friction coefficient; Px - special pressure, N/mm2; x -meeting area of the lubrication and detail, mm2.
Axial force (P ) is determined through the following formula:
P = m^uz Pox m dT '
(3)
here ms - mass of the lubrication, kg; Suz - longitudinal gait, mm/sec; T - time, s; Q-N - forces difference is determined by the following expression:
Q - N = C - C2^~, 2
(4)
here C1 and C2 - accordingly, firmness of the internal and external bows, N/mm; 5 - distance between the ends of the rings in -th condition, mm.
Considering expression (5) in expression (4), finally the following expression can be obtained for the forces difference (Q-N):
Q - N = (C1 - C2 ) ^ or Q - N = (C1 -C2)ri sin9,-. (6)
Normal reaction force of the lapped surface of the detail is determined by the following formula:
P = P tX,
n x. t/w
(7)
here Px t - special pressure, N/mm2; x - meeting area of the lubrication with detail, mm2.
Fd force characterizing the rotating movement of the detail is expressed by the following formula:
F - dl Fd - mdet ..,-2 ' d T
(8)
here mdet - mass of the detail, kg; ^ - angle dislocation of the detail, rad.
Friction force occurred in the rotating movement of the lubrication (F ) is determined by the following formula:
„ ; nr
Fs = ^Px 11-ф,
' t 180°
(9)
here, l - length of lapped surface, mm; (nr/180°)^ - the length of the arc of contact, mm;
Considering expressions (2), (3), (6)-(9) in expression (1), the following system is obtained:
dS
Px +Vpx, t X-ms-f = 0 d!
Py + (1 - c2 ) sin Ф; - Px, t X = 0;
d2m „ , nr
Pr - mdet—T + ^Px 11-Ф = 0.
r detd!2 , t 180°
(10)
P - Fd + F^ = 0.
Eziz Sarvan Shirvan
In general, Px force is directed horizontally and calculated to determine gait movement, Py force is directed to perpendicularly to the axle of the detail and is calculated to determine the firmness of technological system (MDTB), P force is directed to main movement and is calculated
z
to determine the torque moment. Empirically, it was determined that Px - axial, Py - radial and Pz - tangential shear forces are changed in the ratio of Pz : Py : Px = 1: 0,40 : 0,25 for the given processing condition. In case of the change of the factors such as cutting regime elements, physical-mechanical indicators of the detail, geometrical parameters of lubrication head, this ratio will be changed at certain level. Thus, it is necessary to determine the optimal values of the organizers of shear force to obtain the surface having required accuracy and quality.
In Fig. 3 it is given graphical description of the forces influencing the lapping process normally and axially. As it is shown in the graphic, the sum of the forces occurred by the bows directed to the centre of the detail-N and normal reaction force P is in the same direction, the sum of the forces
n '
occurred by the bows directed from the centre of the detail-Q is in the opposite direction. As well as friction force occurred
in the forward-back movement of lubrication - F is directed
si
into the opposite direction in respect of P -axial force.
Fig. 3. Graphical determination of forces influencing lapping process
Upon Fig. 3, it can be written:
P + Q + F - N - P = 0
ox n
d5,
-u + (i - C2 ) sin 9, + ^PX, t x-Px, t X = 0.
dT
(11)
(12)
If we exclude Px t - in expression (12) out of the brackets, we will get:
dS,
-u- + ( -C2) srn9, + px, t (x-x) =
dT
(13)
It can be determined the value of the special pressure from expression (13) by the following formula:
dS,
m—— + (C -C V sinm.
s dT y 1 2 1 1
(14)
in turn, significantly affects the nature of the wear and tear, thus the accuracy, quality and processing performance. Smooth or abrupt changes in the kinematic parameters of the lapping process in many cases are decisive in assessing the stability of the process [2; 14]. For a more complete study of the various kinematic factors affecting the wear pattern of the working surface of the lap, it is also necessary to take into account the forces that characterize the movement, the friction force, the friction coefficient, the specific load, etc.
The nature of the movement of the sample and lap, the variability of the speeds of processing, in most cases, are the main determining factors in the study of the technological capabilities of the process of lapping.
Determining the speed of rotation of the part in the process of lapping the internal surfaces of cylindrical parts is reduced to solving an equation of the type
P - F. + F = 0, or F. = P + F ,
7 d ' d 7
(15)
where Fd - force characterizing the rotating movement of the detail, N; Fs - friction force occurred in the rotating movement of the lubrication, N.
P is the tangential component of the cutting force:
P = P S ,
7 X, f O'
(16)
where So - the average total cross section of chips, mm2.
The average cross section of So chips is determined by the formula:
S„
Venl t,, '
(17)
where Ve - is the elementary volume of the material being removed, mm3; n - number of grains per 1 mm2 surface, pcs; l - is the width of the surface of the lapped hole, mm; ty -the average total area of chips, mm2
Substituting (17) into (16) we get for P :
P = P
Vnl
Substituting (18), (8), (9) into (15) we get:
„ Venl d2m nr
Px t—--mdet—y + ^Px 11-9 = 0.
x' t t dT2 ' t 180°
(18)
(19)
After a series of elementary mathematical transformations, we obtain (19)
^ = ^ f vn + 9
dT2 mdet f ty 180
(20)
Integrating once over T we get the expression of the angular velocity w:
_d9 _ 1 f _ dT _ m J
P
f Venl nr ^
+ -° 9
V fy 180
dT.
(21)
A strictly defined kinematic relationship between the values of the kinematic parameters is established after setting up the machine when the kinematic chain is closed. Investigation of the kinematic features makes it possible to find geometric and kinematic dependencies, on the basis of which a mathematical form is used to determine the descriptive laws that occur during processing. In connection with the kinematic parameters, the linear and angular velocities change, which,
Thus, the value of the specific load is recorded in the form: d5
> = — I
m. J
Px, t dS,
ms-.Ür + (C1 - C2 )ri Sin9;
d!
x(i-v)
m——+(C -c, )r sin9,
s dT y 1 2 ' 1
x(i-v)
Venl , nr
-+ Vl-° 9
V ^ 180
(22)
dT.
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27
F
P
Q
y
or
m
s
m
œ
Px, t =
PECULIARITIES OF THE DEVELOPMENT OF DEVICES BASED ON NANOSTRUCTURED MATERIALS
The linear speed of parts is determined from the condition Vd = or, (23)
where, r is the radius of lap.
The final expression characterizing the linear velocity of the part is:
V =-x
mdet
dS,„
x( 1 -ц)
Venl nr + ц1-г ф
V ty 180
(24)
dl.
CONCLUSIONS AND RESULTS
Cutting process is characterized by the joint influence of axial - Px, radial - Py and tangential - Pz in the processing with the lapping. Obtained analytic expressions can be realized in the subsequent experimental researches and used in the engineering calculations of the technological process of the processing with lapping.
The kinematic characteristics of the operation of the shear forces generated during the lapping process were analyzed on the basis of the equations of the equilibrium system and the main parameters of the process were determined. The degree
of influence of technological parameters on the formation of surfaces and the course of the processing process was determined. The construction of a new lapping tool designed for the processing of internal cylindrical surfaces, the scheme of the lapping operation and a graphical description of the forces acting on the process are given.
Based on the analytical analysis, the relevant geometric diagram and mathematical regularities were obtained, and correlations were established between kinematic parameters (angular velocity, friction coefficient, linear velocity, length of lapped surface and radius of detail).
Based on the analysis of kinematic properties, the dependences of geometric and kinematic parameters and the calculations made on their basis, mathematical formulas describing the course of the processing process were obtained.
Depending on the kinematic parameters, the performance of the lapping changes linear and angular velocities, which have a significant impact on machining accuracy, surface quality and productivity. Fluctuating or abrupt changes in the kinematic parameters of lapping process often have a decisive effect on the stability of the process.
Thus, taking into account the kinematic characteristics of the lapping process, analytical expressions were derived to determine the main parameters of the process. These expressions can be used in engineering calculations and allow to determine the optimal values of processing characteristics.
References
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5. Swan R.J. Composite Lapping materials and Diamond Compounds. Lnd Diam. Rev. 1999. No. 29. 349 p.
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Литература
1. Perovic B. Handbuch Werkzeugmaschinen. Berechnung, Auslegung und konstruction. Hanser-Verlang. Mbnchen Wien, 2006. 832 s.
2. Lishtenberger H. Spanmeugenleistung beim Flachlappen. Werkstattstechnik und Maschenbau. 1995. Ir. 45. Heft. 4. 8 s.
3. Matsinada M. Fundamental Studies of lapping. Report of the Institute of Industrial Science the University of Tokio. 1986. No. 16. Vol. 2. 105 p.
4. Pursche G. Einflubgroben des Lappdemischesbeim Flarhlappen. Fertidungstechnik und Betrieb. 1995. Bd. 15. 1. 4 s.
5. Swan R.J. Composite Lapping materials and Diamond Compounds. Lnd Diam. Rev. 1999. No. 29. 349 p.
6. www.dissertation.com
7. www.globalsecurity.org
8. www.hydratech-industries.com
9. www.mashin.ru/eshop/journals/vestnik-mashinostroeniya
10. Yang C.L. Optimizing the glass fiber cutting process using the Taguchi methods and Grey relational analysis. New Journal of Glass and Ceramics. 2011. No. 1. Pp. 13-19.
11. Крагельский И.В. Трения и износ. М.: Машгиз, 1962. 462 с.
12. Макаров А.Д. Оптимизация процессов резания. М.: Машиностроение, 1996. 278 с.
13. Масловский В.В. Доводочные и притирочные работы. М.: Высшая школа. 1971. 278 с.
14. Орлов П.Н. Алмазно-абразивная доводка деталей. М.: НИИ-МАШ, 1972. 43 с.
15. Яшерицын П.И. Тонкие доводочные процессы обработки деталей и приборов. Минск: Наука и техника, 1996. 328 с.
Статья проверена программой Антиплагиат. Оригинальность - 97%
Рецензент: Горбачевский Е.В., канд. техн. наук; начальник Департамента интеллектуальной собственности, Группы Компаний «Специальные системы и технологии» (ГК «ССТ»)
Статья поступила в редакцию 15.06.2020, принята к публикации 20.08.2020 The article was received on 15.06.2020, accepted for publication 20.08.2020
ABOUT THE AUTHOR
Eziz Sarvan Shirvan, aspirant at the War College of the Armed Forces of the Ministry of Defense of the Republic of Azerbaijan. Baku, Republic of Azerbaijan. E-mail: [email protected]
СВЕДЕНИЯ ОБ АВТОРЕ
Азиз Сарван Ширван оглу, аспирант Военной Академии Вооруженных сил Азербайджанской Республики. Баку, Республика Азербайджан. Е-mail: [email protected]
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