The results of the study of using the end-type heads based on permanent magnets for polishing flat surfaces of ferromagnetic parts on standard metal-working equipment are presented in the work. The possibility of a highly efficient achievement of the roughness of flat surfaces up to Ra < 0.05 μm with the initial Ra > 1–2 μm with removing of the heredity of the machining in the form of microwaves obtained in the face milling operation was shown. Based on the results of the analysis of the process of dispergation of the material was analyzed the influence of the magnetic field gradient the intensity of the magneto-abrasive machining of flat ferromagnetic surfaces by heads, which form a magneto-abrasive tool in the shape of a “brush” and “half of torus”. The influence of technological process parameters: the rotation speed of the working heads, the sizes of the working gap, the technological feed on the character of the change in the microgeometry of the machined surface were investigated. The machining conditions, under which occur the preferential machining of micro peaks or micro valleys on a rough surface, were identified. It was determined that the rational conditions of the magneto-abrasive machining of flat ferromagnetic surfaces are: the rotation speed of the working heads 900 rpm, the gap size between the machined surface and the working surface of the head 2.5–4.0 mm and the working feed 10–15 mm/min. Keywords: finishing, roughness, polishing, permanent magnet, magneto-abrasive tool.
Проблематика. В современном производстве возникает необходимость в финишной обработке поверхностей стальных деталей с нулевой и малой кривизной с целью снижения шероховатости и получения выглаженного микропрофиля. Актуальным является создание мобильного, универсального подвижно-скоординированного абразивного инструмента, обладающего широким спектром его использования на станках разных типов. Для этого необходимо провести исследования по влиянию не только типа магнитно-абразивного порошка, а и его формы и размеров на эффективность обработки плоских поверхностей головками торцевого типа с постоянными магнитами повышенной мощности, а и определить рациональные условия их эксплуатации. Цель исследования. Целью данной работы было определение эффективности процесса магнитно-абразивной обработки торцевыми головками на постоянных магнитах плоских ферромагнитных поверхностей магнитно-абразивными порошками различных типов, с разной формой частиц и величиной рабочего зазора. Методика реализации. Исследование выполняли на плоских образцах из стали 45 с предварительной их подготовкой торцевым фрезерованием и шлифованием. Их обработку выполняли головкой, на рабочем торце которой формируется магнитно-абразивный порошок в виде щетки, при разных рабочих зазорах. Результаты исследования. В работе приведены результаты исследований магнитно-абразивной обработки плоских поверхностей головками с постоянными высокомощными магнитами. При исследовании возможности использования разных по типу, форме и размерам частиц магнитно-абразивных порошков показано, что целесообразным является использование порошков с оскольчатой формой частиц с большим количеством режущих микрокромок на поверхности частиц и с малым радиусом их округления. Полученные результаты позволяют предположить, что процесс формирования магнитно-абразивного инструмента, непосредственно его форма и характер расположения магнитно-абразивных частиц и их групп по отношению к обрабатываемой поверхности будут оказывать существенное влияния на конечный результат обработки. Выводы. В результате экспериментальных исследований процесса магнитно-абразивной обработки плоских стальных поверхностей порошками различных типов и зернистости, показано возможность обеспечения шероховатости поверхности с Ra < 0,05 мкм с одновременным удалением волнистости поверхности. Установлено, что решающим технологическим ориентиром при достижении минимальной шероховатости является величина рабочего зазора, которая должна быть не меньше 1,5 мм. Ключевые слова: Шероховатость, магнитно-абразивная обработка, постоянный магнит, рабочий зазор, магнитноабразивный порошок, микропрофиль. Flat surfaces machining by the magneto-abrasive method with permanent magnet end-type heads 1. The influence of the type of magneto-abrasive powder on the effectiveness of the magneto-abrasive machining Maiboroda Victor, Dzhulii Dmytro, Zelinko Andrii Background. The modern production requires finishing surfaces of steel parts with zero and small curvature in order to reduce roughness and obtain a smoothed microprofile. Actual is th...
Investigations of the magneto-abrasive machining (MAM) process of ferromagnetic flat surfaces by three types of end heads were carried out. The nature of the change in the magnitude of the magnetic induction in the working zones was determined. The influence of technological parameters of the machining process was investigated, such as the feed rate of the working heads, the frequency of their rotation about their axis, the size of the working gaps on the change in the parameters of the microroughness of the machined surfaces - Sa, Sp, Sv, the frequency distribution of heights microroughness and size of the supporting surface of the profile. It was shown that the level of roughness achieved after MAM is practically the same and does not exceed, under rational conditions of the MAM process, the values Sa = 0.05-0.07 μm, Sp = 0.2 μm and Sv = 0.39 μm with the only difference that the MAM process by the heads of the "brush-half of torus" type are being realized with increased productivity, especially in terms of reducing waviness and individual elements of the heredity of machining, determined by such factors as depth and feed rate during milling. The kinetics of the formation of a microprofile of surfaces is shown under various technological conditions of the MAM process.
Investigation of the magneto-abrasive machining process of flat surfaces of parts made of ferromagnetic material steel 45 by the end heads based on high-power permanent magnets, which form the magneto-abrasive tool of the "brush" type, was carried out. For ensuring the high efficiency of the magneto-abrasive machining process, an analysis of the machining by heads on the working surfaces of which located protrusions of various shapes, sizes and configurations was carried out. Twelve types of working surfaces were investigated. The control of magneto-abrasive machining process efficiency was curried for the changing of the parameter Ra, the value of the relative roughness and the rate of its change, the size of the surface's relative reference profile length from the section level of the formed microprofile and the parameter of geometric heredity obtained during the machining. It has been determined that the most rational design of the working surface of the end head with the magneto-abrasive tool of the "brush" type was the surface with 9-12 radial triangular protrusions located on it. Using of such heads provides a highly efficient form of the roughness of machined surfaces with Ra < 0.03 µm with an initial Ra of 0.8 µm obtained after face milling. At the same time, microwaves had been formed after milling was almost eliminated. The kinetics formation of the relative reference profile length from the section level was analyzed by the nature of its size change. It was shown that at the initial stage, the predominant removal of micro peaks had occurred, and then micro valleys were actively machined with further smoothing of the microprofile.
The features of magneto-abrasive machining of taps for metric thread cutting were investigated. The calculation method of integral intensity of the magneto-abrasive machining of the working surfaces of the taps by the quantitative values of normal and tangential components of moving speed of the quasi-stable volumes of the magneto-abrasive tool was developed. Based on the results of calculations, it was possible to predict the probable influence of the taps’ location in the working zone on the quality and efficiency of machining their working surfaces. The calculation method is relevant for taps of all diameters with a profile angle of 60°. The working surfaces of the tool would not be effectively machined if the location angle of taps to the plane of the working zone of the machine equals 20–60°. Depending on the expected major polishing or strengthening effect of magneto-abrasive machining, the taps are required to be located at an angle of 60–90° to the plane of the working zone of the machine.
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