Simulation and analysis of abrasive particles dynamics behavior during magnetic particles grinding on inner wall of pipe fitting
-
摘要: 为探究磁性磨粒在管件研磨过程中的动力学行为，对其研磨过程进行离散元仿真，并分析其运动轨迹和磨削力随管件转速和加工间隙的变化；通过单磨粒球运动及磁粒研磨试验，验证磁场力模型的准确性与粒子运动学行为可视化的可行性。结果表明：随管件转速提高，磁性磨粒在离心力作用下向加工区域外运动，且加工间隙越大越容易被“甩飞”；在达到临界转速之前，随管件转速提高，磨削力减小，材料去除效率提升。当管件转速由400 r/min提高至临界转速，加工间隙为2 mm和4 mm时，磨削力分别下降5.4 μN和2.3 μN，材料去除效率明显提升；当加工间隙为6 mm时，磨削力变化较小，且当转速大于临界转速650 r/min时，材料去除效率下降。同时，材料去除量在达到临界转速之前随管件转速提高而增大，但加工间隙的增大会使临界转速降低；且材料去除量的变化趋势与仿真结果一致，验证了仿真分析的可靠性。Abstract: To explore the dynamic behavior of magnetic abrasive particles in the grinding process of pipe fittings, the grinding process of magnetic abrasive particles was simulated using discrete elements. The changes in motion trajectory and grinding force with the speed of pipe fittings and the processing gap were analyzed. Single abrasive particle ball motion and magnetic particle grinding test were conducted to verify the accuracy of the magnetic field force model and the feasibility of visualizing the particle kinematic behavior. The results show that as the speed of the pipe fittings increases, the magnetic abrasive particles move outside the processing area due to centrifugal force, and the larger the processing gap, the easier they are "thrown away". Before reaching the critical rotation speed, the grinding force decreases, and material removal efficiency increases with the increase in pipe rotation speed. When the pipe rotation speed increases from 400 r/min to the critical rotation speed and the machining gaps are 2 mm and 4 mm, the grinding forces decrease by 5.4 μN and 2.3 μN respectively, leading to a significant improvement in material removal efficiency. However, with a machining gap of 6 mm, the grinding force changes little, and when the rotation speed exceeds the critical rotation speed of 650 r/min, material removal efficiency decreases. Additionally, the material removal amount increases with the increase in pipe rotation speed before reaching the critical rotation speed, but increasing the processing gap reduces the critical rotation speed. The change in material removal amount aligns with the simulation results, validating the reliability of the simulation analysis.
-
图 2 不同磁场下磁性磨粒的磁场力
Figure 2. Magnetic field force of magnetic abrasive particles under different magnetic fields
图 6 不同参数下磨粒系统的速度场矢量图
Figure 6. Velocity field vector diagram of abrasive particle system with different parameters
图 7 不同加工间隙下磨削力与材料累计去除占比随管件转速的变化
Figure 7. Variation of grinding forces and cumulative material removal ratios with pipe rotation speeds under different machining clearances
图 10 管件的微观形貌与表面粗糙度
Figure 10. Microscopic morphology and surface roughness of pipe fittings
表 1 材料参数
Table 1. Material parameters
类型 密度 ρ /（kg·m−3） 弹性模量 E / Pa 泊松比 ν 管件 4 510 4.48 × 1010 0.38 磨粒 5 548 6.09 × 109 0.29 
下载: 导出CSV
表 2 接触参数
Table 2. Contact parameter
类型 碰撞恢复系数 e 静摩擦系数 μs 滚动摩擦系数 μr 磨粒与磨粒 0.20 0.50 0.01 磨粒与管件 0.15 0.50 0.01
下载: 导出CSV
-
[1] 刘文浩, 陈燕, 李文龙, 等. 磁粒研磨加工技术的研究进展 [J]. 表面技术,2021,50(1):47-61. doi: 10.16490/j.cnki.issn.1001-3660.2021.01.004LIU Wenhao, CHEN Yan, LI Wenlong, et al. Research progress of magnetic abrasive finishing technology [J]. Surface Technology,2021,50(1):47-61. doi: 10.16490/j.cnki.issn.1001-3660.2021.01.004 [2] QIAN C, FAN Z H, TIAN Y B, et al. A review on magnetic abrasive finishing [J]. The International Journal of Advanced Manufacturing Technology,2020(112):1-16. [3] 潘明诗, 陈燕, 张东阳. 仿形磁极头对电磁研磨管件内表面形成的影响 [J]. 中国表面工程,2022,35(6):274-285.PAN Mingshi, CHEN Yan, ZHANG Dongyang. Effect of profiling magnetic pole head on the inner surface of electromagnetic finishing pipe fittings [J]. China Surface Engineering,2022,35(6):274-285. [4] 郭龙文, 杨能阁, 陈燕. 磁力研磨工艺对整体叶盘表面完整性的影响 [J]. 中国表面工程,2013,26(3):10-14. doi: 10.3969/j.issn.1007-9289.2013.03.002GUO Longwen, YANG Nengge, CHEN Yan. Influence of magnetic abrasive finishing technology on surface integrity of vane-integrated disk [J]. China Surface Engineering,2013,26(3):10-14. doi: 10.3969/j.issn.1007-9289.2013.03.002 [5] QUAN H J, JIAO A Y, LI Z Z, et al. Process research of seal ring groove based on magnetic abrasive finishing [J]. International Journal of Manufacturing Technology and Management,2018,32(6):565-579. doi: 10.1504/IJMTM.2018.095035 [6] 陈燕, 宋宗朋, 李昌, 等. 磁研磨法抛光40Cr钢管件内表面的影响因素 [J]. 中国表面工程,2015,28(4):62-69. doi: 10.11933/j.issn.1007-9289.2015.04.008CHEN Yan, SONG Zongpeng, LI Chang, et al. Influencing factors on polishing inner surface of 40Cr steel pipe fittings with a magnetic grinding method [J]. China Surface Engineering,2015,28(4):62-69. doi: 10.11933/j.issn.1007-9289.2015.04.008 [7] 陈燕, 李龙邦, 曾加恒, 等. 航空发动机钛合金导管内表面精密研磨试验研究 [J]. 航空制造技术,2018,61(9):40-46. doi: 10.16080/j.issn1671-833x.2018.09.040CHEN Yan, LI Longbang, ZENG Jiaheng, et al. Experimental study on precision grinding of titanium alloy conduit inner surface in aero-engine [J]. Aeronautical Manufacturing Technology,2018,61(9):40-46. doi: 10.16080/j.issn1671-833x.2018.09.040 [8] 陈燕, 张广彬, 韩冰, 等. 磁力研磨法对陶瓷管内表面超精密抛光技术的试验研究 [J]. 摩擦学学报,2015,35(2):131-137. doi: 10.16078/j.tribology.2015.02.002CHEN Yan, ZHANG Guangbin, HAN Bing, et al. Experimental investigation of magnetic abrasive finishing for super precision polishing of inner surface of the ceramic tube [J]. Tribology,2015,35(2):131-137. doi: 10.16078/j.tribology.2015.02.002 [9] 徐会, 康仁科, 刘冬冬, 等. 磁力研磨法去除航空发动机涡轮轴内表面积碳的试验分析 [J]. 表面技术,2020,49(1):336-342, 355. doi: 10.16490/j.cnki.issn.1001-3660.2020.01.040XU Hui, KANG Renke, LIU Dongdong, et al. Experimental analysis of removing the carbon deposition by magnetic grinding from the inner surface of an aero-engine turbo-shaft [J]. Surface Technology,2020,49(1):336-342, 355. doi: 10.16490/j.cnki.issn.1001-3660.2020.01.040 [10] 韩冰, 刘立鑫, 陈燕. 磁力研磨法加工弯管内表面的工艺参数优化 [J]. 中国机械工程,2015,26(6):814-817. doi: 10.3969/j.issn.1004-132X.2015.06.020HAN Bing, LIU Lixin, CHEN Yan. Optimization of process parameters on magnetic abrasive finishing to inner surface of bending pipe [J]. China Mechanical Engineering,2015,26(6):814-817. doi: 10.3969/j.issn.1004-132X.2015.06.020 [11] JAYSWAL S C, JAIN V K, DIXIT P M. Modeling and simulation of magnetic abrasive finishing process [J]. The International Journal of Advanced Manufacturing Technology,2005,26(5/6):477-490. [12] JAYSWAL S C, JAIN V K, DIXIT P M. Magnetic abrasive finishing process–A parametric analysis [J]. Journal of Advanced Manufacturing Systems,2005,4(2):131-150. doi: 10.1142/S0219686705000655 [13] 胡国明. 颗粒系统的离散元素法分析仿真 [M]. 武汉: 武汉理工大学出版社, 2010.HU Guoming. Analysis and simulation of granular system by discrete element method using EDEM [M]. Wuhan: Wuhan University of Technology Press, 2010. [14] 王国强, 郝万军, 王继新. 离散单元法及其在EDEM上的实践 [M]. 西安: 西北工业大学出版社, 2010.WANG Guoqiang, HAO Wanjun, WANG Jixin. Discrete element method and its practice on EDEM [M]. Xi'an: Northwestern Polytechnical University Press, 2010 [15] MISHRA B K. A review of computer simulation of tumbling mills by the discrete element method: Part I—Contact mechanics [J]. International Journal of Mineral Processing,2003,71(1):73-93. [16] 田雨. 基于EDEM的滚磨光整加工机理分析和参数优化 [D]. 太原: 太原理工大学, 2014.TIAN Yu. Mechanism analysis and parameter optimization of barrel finishing based on EDEM [D]. Taiyuan: Taiyuan University of Technology, 2014. [17] 陈燕, 张旭. 铁基白刚玉磁性磨料的制备工艺 [J]. 金刚石与磨料磨具工程,2013,33(3):12-16. doi: 10.13394/j.cnki.jgszz.2013.03.013CHEN Yan, ZHANG Xu. Preparation technology of iron-based white corundum magnetic abrasive grits [J]. Diamond & Abrasives Engineering,2013,33(3):12-16. doi: 10.13394/j.cnki.jgszz.2013.03.013 [18] 徐建成, 徐建民. 矿粒所受磁力计算公式的几个问题探讨 [J]. 有色金属,2005,57(1):77-80.XU Jiancheng, XU Jianmin. Some problems in calculation formula of mineral particle magnetic attraction [J]. Nonferrous Metals,2005,57(1):77-80. [19] 杨欢, 陈松, 张磊, 等. 脉冲电磁场辅助平面磁粒研磨加工试验 [J]. 表面技术,2022,51(2):313-321. doi: 10.16490/j.cnki.issn.1001-3660.2022.02.031YANG Huan, CHEN Song, ZHANG Lei, et al. Experimental study on pulsed electromagnetic field assisted planar magnetic abrasive finishing [J]. Surface Technology,2022,51(2):313-321. doi: 10.16490/j.cnki.issn.1001-3660.2022.02.031 [20] 舒坤, 孙岩, 陈燕. 超声振动辅助磁粒研磨技术的研究进展 [J]. 振动与冲击, 2023, 42(6): 39-54SHU Kun, SUN Yan, CHEN Yan. Review of research progress on ultrasonic assisted magnetic abrasive finishing technology [J]. Journal of Vibration and Shock, 2023, 42(6): 39-54 -
点击查看大图
图(11) / 表(2)
计量
- 文章访问数: 125
- HTML全文浏览量: 51
- PDF下载量: 15
- 被引次数: 0
邮件订阅
RSS
