氧化锆陶瓷的切向超声辅助镜面磨削研究

随着5G技术的快速发展，市场对精细陶瓷结构件的生产效率、制造成本、加工精度等提出了新的要求。其中，氧化锆陶瓷是使用最普遍的典型精细陶瓷材料，但因具有高脆性、低断裂韧性等特点，致使精密加工难度大，一直困扰着其应用前景。由于传统磨削技术在陶瓷加工中仍存在加工效率低，砂轮磨损快，制造成本较高等问题。因此，需要开发新的工艺技术以突破精细陶瓷结构件的加工技术瓶颈。本文将以氧化锆陶瓷作为研究对象，提出了切向超声辅助镜面磨削的精密加工方法，为陶瓷加工技术提供必要的理论支持和实践经验，具有重要的科研意义。

围绕圆弧面和平面结合的典型氧化锆陶瓷结构件高效高精度加工目标，本文开展了切向超声辅助磨削加工原理研究及实验装置的搭建、超声辅助修整金刚石砂轮的实验研究、切向超声辅助磨削氧化锆陶瓷基础特性研究以及曲面结构的切向超声辅助磨削路径研究。论文首先立足于研究背景，分析了现有精细陶瓷材料与精细陶瓷曲面加工技术、砂轮修整的研究动态；明确了现有技术的特点与不足，基于此提出了本文的研究内容与技术路线。阐述了切向超声辅助磨削曲面和平面的加工原理，开展了磨粒运动轨迹仿真，明确了超声对磨粒磨削速度和加速度的增益效果，分析了陶瓷材料塑性去除的临界深度；基于提出的加工方法，搭建了实验装置，确定了砂轮选型规则与砂轮修整装置，并验证了装置的可靠性。

论文提出了超声辅助绿色碳化硅（Green Silicon Carbide，简称GC）杯形修整轮修整金刚石砂轮的方法，通过单因素实验明确了超声对修整力的变化、砂轮圆度误差与直线度误差、有效磨粒分布与微观形态以及砂轮修整比的影响规律，并开展了有无超声辅助砂轮修整对磨削氧化锆陶瓷的对比实验；总结了振幅对金属/树脂结合剂金刚石砂轮修整的影响特性。结果表明，因砂轮径向跳动对实际修整切深的影响，修整中的修整力随着砂轮的旋转而周期性变化，其峰值随修整时间逐渐减小并趋于稳定，但随着超声振幅的增加而减小。超声辅助修整后的金刚石砂轮圆度和直线度得到明显改善，在A_p-p=4.7 μm时，修整1.5 min之后，砂轮圆度误差和直线度误差相比于无超声条件分别降低了约23%和17%。同时，随着超声振幅的增加，修整过程中的圆度和直线度误差减少率增加，修整的时间缩短，可以快速达到修整目标。

基于切向超声辅助镜面磨削基础实验，研究了氧化锆陶瓷平面磨削单因素实验中工艺参数对氧化锆陶瓷表面形貌和表面粗糙度、磨削力和磨削温度的影响规律，以及有无超声作用下砂轮的磨损状况；基于实验结果着重阐述了磨粒切削轨迹的相交现象，深入研究了切向超声辅助磨削加工对改善表面质量的内在原因，同时就切向超声辅助磨削加工改善砂轮的磨损状况，提高砂轮使用寿命的效果开展了分析。结果表明，切向超声辅助磨削可以实现氧化锆陶瓷的镜面加工，在A_p-p=4.66 μm时，与传统磨削（A_p-p=0）相比，工件表面粗糙度下降43.8%。法向磨削力和磨削温度也随着超声振幅的增大而下降。此外，切向超声辅助磨削加工可以改善砂轮的磨损状况，减少砂轮上磨粒的脱落，延长砂轮使用寿命。

最后，以一具体曲面为对象，设计了曲面镜面磨削实验研究的方法，选取α=0°，α=45°，α=90°三种砂轮的走刀方向。研究了不同路径对工件表面质量和轮廓的影响规律以及砂轮的磨损情况；基于单颗金刚石划擦实验，分析了单颗磨粒在不同路径下的材料去除方式；建立了磨削加工模型，对曲面工件表面形貌和表面粗糙度进行了数值仿真，阐述了表面微观几何形貌的影响因素，描述了表面空间磨削运动轨迹，并对加工结果与趋势进行了预测与验证。研究结果表明，当α=0°时，工件的面粗糙度最小，且沿着宽度方向轮廓误差也最小，但在沿着曲率方向轮廓误差最大；而α=90°的路径下，面粗糙度变大，沿着曲率方向轮廓误差最小；α=45°的路径下表面质量最差。砂轮的磨损以磨粒磨损为主，α=45°的路径下，砂轮磨损的形式包括磨粒磨损和结合剂破碎。α=45°的路径时，材料脆性破碎的几率增高，从而形成了不同的表面加工质量。

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