Surface Finishing Theory and New Technology

505 Pages·2018·18.761 MB·English

by  Shengqiang Yang, Wenhui Li

Shengqiang Yang · Wenhui Li
Surface Finishing
Theory and New
Technology
Surface Finishing Theory and New Technology
Shengqiang Yang Wenhui Li
(cid:129)
Surface Finishing Theory
and New Technology
123
Shengqiang Yang WenhuiLi
Collegeof MechanicalEngineering Collegeof MechanicalEngineering
Taiyuan University of Technology Taiyuan University of Technology
Taiyuan Taiyuan
China China
ISBN978-3-662-54131-9 ISBN978-3-662-54133-3 (eBook)
https://doi.org/10.1007/978-3-662-54133-3
JointlypublishedwithNationalDefenseIndustryPress,Beijing,China
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printbookfrom:NationalDefenseIndustryPress.
LibraryofCongressControlNumber:2017956322
Translation from the Chinese language edition:《表面光整加工理论与新技术》Biao Mian Guang
ZhengJiaGongLilunYuXinJishuby杨胜强YangShengqiang,©NationalDefenseIndustryPress
2011.AllRightsReserved.
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Preface
TaiyuanUniversityofTechnology(TYUT)hasbeenresearchingandspreadingthe
applicationofsurfacefinishingtechnologyforabout30yearsandisoneoftheearly
domestic research institutes carrying out the free abrasive finishing technology.
TYUThasobtainedanumberofachievementsandpatents.Oneoftheprojectswas
listed in the national key project of scientific and technological achievements.
TYUT was awarded one prize for Science and Technology Progress of China and
two prizes for Science and Technology Progress of Shanxi province. Based on the
former research results, Professor Shichun Yang published a monograph “surface
quality and finishing technology” supported by high-standard writing publication
fund of China Machine Press in 2000. This monograph won extensive recognition
from all sectors of society such as colleges, research institutes, and enterprises.
Some colleges are using this book as the textbook for postgraduate or undergrad-
uate students. Some manufacturers have used the new processes and equipment
introduced in this monograph. It is certain that the editor’s original intention has
been realized.
In the past decade, the Finishing Technology Research Institute of TYUT has
been committed to the technical challenge in production. There are four doctoral
theses, respectively, discussing many new theories, technologies, and processes
related to the barrel finishing for shaft parts with large sizes, magnetic abrasive
finishing, fluid magnetic abrasive finishing, and two-phase flow finishing. These
thesesaresupportedby NationalNatural Science FoundationofChina, Innovation
Funds for Small and Medium Corporation from Nation’s Technology Ministry,
Shanxi Natural Science Foundation, Shanxi Scientific and Technological Project,
Shanxi Science and Technology Research and Development Program, and Shanxi
Foundation for Returned Scholars. Our institute has been cooperating with
Langfang branch of China North Industries Group Corporation (Langfang Beifang
Tianyu Mechanical andElectricalTechnologyCo.,Ltd.) ondeveloping manynew
finishing equipments adapting to market demand. The research achievements have
been successfully used in military-industrial enterprises, civil enterprises, and
foreign-fundedenterprises.Theseenterprisesachievedbettereconomicbenefitsand
social benefits. Based on the necessity in practice of teaching, scientific research,
v
vi Preface
and manufacturing, the monograph “surface finishing theory and new technology”
was published in 2011, which was supported by publishing fund of National
Defense Science and Technology Books. The principle of this monograph is that
themonographfocusesontheresearchresultsandachievementsofauthors.Italso
emphasizesthesystematicnessandintegrity oftheory,experiment,simulation,and
application and summarizes the practical finishing methods at home and abroad.
Thismonographisintendedforthepracticingengineerswhoengagedinmachinery
manufacturing and related engineering field, as well asfor scientific personnel and
university teachers and students.
In this revision, authors have made some modifications and improvements for
every chapter. Chapter 1 supplemented some concepts and explanation. Chapter 2
added simulation and analysis of centrifugal barrel finishing process; types of
vibratory barrel finishing process are improved, preparation process of the media
are added, and some application cases are updated. Chapter 3 increased one
preparation method of magnetic abrasive using the high-energy ball milling.
Chapter4increasedSect.6,andthesurfacemodificationofFMAisputforwardto
change the surface chemical properties of the particles in this section. Chapter 5
increased Sect. 6, and this section explored the finishing principle, fluent field
simulation, and finishing effects of the two-phase compulsive circulation flows
finishing.
Thismonographiscomprisedof5chapters.Chapter1introducestheconceptof
surface quality and surface finishing technology, and the development offinishing
technology. Chapters 2–5 explore the finishing mechanism, equipment, influence
factors, finishing effects and applications of barrel finishing, magnetic abrasive
finishing, fluid magnetic abrasive finishing, and two-phase flow finishing,
respectively.
ThismonographiswrittenbySheng-qiangYang,Wen-huiLi,etal.Thisbookis
written in the form of brainstorm and division writing. The breakdown of this
monographisChap.1iswrittenbySheng-qiangYang,Wen-huiLi,Feng-fengWu;
Chap. 2 is written by Wen-hui Li; Chap. 3 is written by Hong-ling Chen,
Yong-gangLi,Zhi-yanHou;Chap.4iswrittenbyWei-dongLiandHuan-wuSun;
Chap. 5 is written by Xiu-hong Li. The book is compiled by Wen-hui Li and
Sheng-qiang Yang. English proofreading is done by Jian-yan Tian, and Yan-qing
Wang,Xiu-zhiWang,Li-pingLiuinourinstitutiontookpartinthetranslation.The
authorsexpress great appreciationto their supports. The authors are grateful tothe
National Defense Science and Technology Publishing Press for the support.
The authors are limited, and this monograph may have some mistakes. We
welcome readers to correct and make valuable comments!
Taiyuan, China Shengqiang Yang
March 2017 Wenhui Li
Contents
1 Surface Quality and Finishing Technology . . . . . . . . . . . . . . . . . . . . 1
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Surface Quality of Part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2.1 Product Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2.2 Part Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2.3 Surface Quality of Part. . . . . . . . . . . . . . . . . . . . . . . . . 3
1.3 Surface Finishing Technology . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.3.1 Connotation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.3.2 Function and Characteristics . . . . . . . . . . . . . . . . . . . . . 14
1.3.3 Classification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.3.4 Finishing Effects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.4 Evaluation of Surface Quality and Selection of Finishing
Methods. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1.4.1 Surface Quality Evaluation . . . . . . . . . . . . . . . . . . . . . . 26
1.4.2 Measurement of Evaluation Indexes . . . . . . . . . . . . . . . 47
1.4.3 The Choice of Finishing Methods . . . . . . . . . . . . . . . . . 53
1.5 Current Situation and Trend of Finishing Technologies. . . . . . . . 59
1.5.1 Brief History and Present Situation . . . . . . . . . . . . . . . . 59
1.5.2 Development Trends . . . . . . . . . . . . . . . . . . . . . . . . . . 61
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
2 Barrel Finishing Technology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
2.1.1 Connotation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
2.1.2 Classification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
2.1.3 Functional Characteristics and Application Scope. . . . . . 69
2.2 Rotary Barrel Finishing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
2.2.1 Finishing Principle and Characteristics. . . . . . . . . . . . . . 72
2.2.2 Main Factors Affecting Finishing Effects. . . . . . . . . . . . 73
2.2.3 Equipment Types and Design . . . . . . . . . . . . . . . . . . . . 74
vii
viii Contents
2.3 Vibratory Barrel Finishing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
2.3.1 Finishing Principle and Characteristics. . . . . . . . . . . . . . 75
2.3.2 Main Factors Affecting Finishing Effects. . . . . . . . . . . . 79
2.3.3 Equipment Types and Design . . . . . . . . . . . . . . . . . . . . 81
2.4 Whirling Barrel Finishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
2.4.1 Finishing Principle and Characteristics. . . . . . . . . . . . . . 88
2.4.2 Main Factors Affecting Finishing Effects. . . . . . . . . . . . 89
2.4.3 Equipment Types and Design . . . . . . . . . . . . . . . . . . . . 91
2.5 Centrifugal Barrel Finishing . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
2.5.1 Finishing Principle and Characteristics. . . . . . . . . . . . . . 94
2.5.2 Main Factors Affecting Finishing Effects. . . . . . . . . . . . 108
2.5.3 Equipment Types and Design . . . . . . . . . . . . . . . . . . . . 116
2.6 Vertical Spindle Barrel Finishing. . . . . . . . . . . . . . . . . . . . . . . . 120
2.6.1 Finishing Principle and Characteristics. . . . . . . . . . . . . . 120
2.6.2 Main Factors Affecting Finishing Effects. . . . . . . . . . . . 131
2.6.3 Equipment Types and Design . . . . . . . . . . . . . . . . . . . . 139
2.7 Horizontal Spindle Barrel Finishing. . . . . . . . . . . . . . . . . . . . . . 144
2.7.1 Finishing Principle and Characteristics. . . . . . . . . . . . . . 144
2.7.2 Main Factors Affecting Finishing Effects. . . . . . . . . . . . 154
2.7.3 Equipment Types and Its Design. . . . . . . . . . . . . . . . . . 164
2.8 Finishing Medium . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
2.8.1 Abrasive Blocks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
2.8.2 Liquid Medium . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
2.9 Mass Finishing Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
2.9.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
2.9.2 Applications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
3 Magnetic Abrasive Finishing Technology . . . . . . . . . . . . . . . . . . . . . 225
3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
3.1.1 Basic Meaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
3.1.2 Force Analysis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
3.1.3 Trajectory of Magnetic Abrasive. . . . . . . . . . . . . . . . . . 230
3.1.4 Finishing Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . 232
3.1.5 Expiration Analysis of Magnetic Abrasive. . . . . . . . . . . 235
3.2 Magnetic Abrasive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
3.2.1 Composition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
3.2.2 Classification and Model . . . . . . . . . . . . . . . . . . . . . . . 239
3.2.3 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
3.2.4 Main Performance Parameters. . . . . . . . . . . . . . . . . . . . 256
3.3 Magnetic Abrasive Finishing Device . . . . . . . . . . . . . . . . . . . . . 272
3.3.1 Composition of Magnetic Abrasive Finishing Device . . . 272
3.3.2 Design of the Magnetic Field Generator . . . . . . . . . . . . 276
3.3.3 Design of Magnetic Pole Head . . . . . . . . . . . . . . . . . . . 287
Contents ix
3.4 Factors Affecting Finishing Effects . . . . . . . . . . . . . . . . . . . . . . 297
3.4.1 Motion Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298
3.4.2 Process Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
3.4.3 Equipment Parameters . . . . . . . . . . . . . . . . . . . . . . . . . 306
3.4.4 Other Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
3.5 Application Example of Magnetic Abrasive Finishing. . . . . . . . . 314
3.5.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314
3.5.2 Finishing Effect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
3.5.3 Application Examples. . . . . . . . . . . . . . . . . . . . . . . . . . 317
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332
4 Fluid Magnetic Abrasive Finishing Technology . . . . . . . . . . . . . . . . 337
4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337
4.1.1 Presentation of the Fluid Magnetic
Abrasive Surface Finishing Technology. . . . . . . . . . . . . 337
4.1.2 Characteristics of the Fluid Magnetic
Abrasive Surface Finishing Technology. . . . . . . . . . . . . 339
4.2 Fluid Magnetic Abrasive Finishing Mechanism . . . . . . . . . . . . . 341
4.2.1 Fluid Magnetic Abrasive Rheological Properties
Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341
4.2.2 Fluid Magnetic Abrasives Finishing Mechanism . . . . . . 344
4.3 Fluid Magnetic Abrasive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348
4.3.1 Composition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348
4.3.2 Preparation Technology . . . . . . . . . . . . . . . . . . . . . . . . 354
4.3.3 Performance Parameters . . . . . . . . . . . . . . . . . . . . . . . . 356
4.4 Fluid Magnetic Abrasive Finishing Device. . . . . . . . . . . . . . . . . 373
4.4.1 Basic Requirements of Finishing Device . . . . . . . . . . . . 373
4.4.2 Magnetic Field Design and Finite Element Analysis. . . . 374
4.4.3 Device Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 381
4.5 Main Factors and Finishing Effects Affecting Fluid Magnetic
Abrasive Performance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 384
4.5.1 Finishing Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 384
4.5.2 Main Affecting Factors. . . . . . . . . . . . . . . . . . . . . . . . . 385
4.5.3 Finishing Effects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 390
4.6 The Surface Modification of Fluid Magnetic Abrasive . . . . . . . . 393
4.6.1 Existent Insufficiencies of Fluid Magnetic Abrasive . . . . 393
4.6.2 The Surface Modification of Fluid
Magnetic Abrasive . . . . . . . . . . . . . . . . . . . . . . . . . . . . 393
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 397
5 Two-Phase Swirling Flow Hole Finishing . . . . . . . . . . . . . . . . . . . . . 401
5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
5.1.1 Presentation of Two-Phase Swirling Flow Hole
Finishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
x Contents
5.1.2 Characteristics of the Two-Phase Swirling Flow Hole
Finishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
5.2 Theory and Numerical Simulation of Swirling Flow . . . . . . . . . . 403
5.2.1 Single-Phase Swirling Flow . . . . . . . . . . . . . . . . . . . . . 403
5.2.2 Two-Phase Swirling Flow. . . . . . . . . . . . . . . . . . . . . . . 419
5.2.3 Simulation of Gas-Particle Two-Phase Swirling Flow. . . 431
5.3 Finishing Mechanism of Gas-Particle Swirling Flow. . . . . . . . . . 435
5.3.1 Formation of Flow Field. . . . . . . . . . . . . . . . . . . . . . . . 436
5.3.2 Force Analysis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 438
5.3.3 Microscopic Motion Feature . . . . . . . . . . . . . . . . . . . . . 445
5.3.4 Finishing Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . 446
5.4 Experimental Device ofGas Particle Two-Phase Swirling Flow
Finishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 449
5.4.1 Overall Design. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 449
5.4.2 Formation Components of the Swirling Flow. . . . . . . . . 450
5.4.3 Other Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 463
5.5 Main Factors and Finishing Effects . . . . . . . . . . . . . . . . . . . . . . 467
5.5.1 Technical Process. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 467
5.5.2 Main Factors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 469
5.5.3 Finishing Performance . . . . . . . . . . . . . . . . . . . . . . . . . 480
5.6 Two-Phase Compulsive Circulation Flow Finishing . . . . . . . . . . 482
5.6.1 Gas-Particle Two-Phase Compulsive Circulation Flow
Finishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 482
5.6.2 Liquid-Particle Two-Phase Compulsive Circulation
Flow Finishing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 486
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 495