Research On Complete Sets Of Mechanical Polishing Technology For Aluminum Wheel Hub Surface

The surface polishing is the important procedure before electroplating for aluminum alloy auto wheel hub(hub), require removal of surface material evenly, without polishing deformation, and the surface roughness Ra of 0.5um or less. However, because of the hub of cast production original surface roughness is large and required polishing large area, and the shape of a complex, diverse, Almost all the hub production enterprises depend on skilled workers for polishing, there are some problems about labor intensive, dust pollution serious, labor shortages, low efficiency, and instable polishing quality, which seriously restricted the development of enterprises.At present, the one hand, foreign mechanical equipment for polishing hub surface, due to its limitations of polishing production methods, making do not generally application to domestic hub manufacturing enterprises for the surface of polishing; the other hand, existing studies of mechanical polishing techniques and automated equipments, etc., for the rough surface of workpiece achieve high-efficient, high-quality polishing, there are some problems and shortcomings.Therefore, in the background as a trial project of new product, Zhejiang Province Science and Technology Department, and Jinhua City key project, in close connection with the actual production, against the mechanical polishing technology for the study of existing problems and deficiencies, this paper studied the high-efficiency, high-quality polishing methods for the rough surface of large workpiece, and studied which the key technologies, developed the corresponding mechanical polishing equipment and control system. These studies will provide effective ideas and reference for the type of workpieces surface polishing, and help solve the problems created by manual polishing mode for hub surface.Against the NC polishing cutter location data generation method for the study existing deficiencies, a multi-abrasive flexible wheel polishing cutter location data generation method based on the constant removal rate coefficient and surface material removal control method are proposed, to ensure that the rapid decrease of workpiece surface roughness and uniform removal of surface material, and improve surface quality. Through the multi-abrasive polishing cutter location data generation and surface material removal simulation, verified the cutter location data generation method is reasonable, And multi-abrasive than single-abrasive polishing rough surface, in the case of the given the same surface material removal depth, the surface material removal more uniform and higher polishing efficiency.For the rotating surface and the radial symmetric distribution surface, a single-station, multi-abrasive linkage mechanical polishing process is presented. Based on the way, to the hub surface polishing as an example, a multi-abrasive polishing machine tool is designed, and developed the corresponding open hardware and software control systems to achieve efficient polishing workpiece surface. Through the surface polishing experiments and production in the multi-abrasive polishing machine tool, polished surface of material removal uniformity and surface smoothing, no deformation occurred, measuring average surface roughness Ra is about 0.5μm. Confirmed the single-station multi-abrasive linkage mechanical polishing and cutter location data generation method are reasonable.For the rotary feature large workpiece with complex surfaces polishing, a swirl-type rolling mechanical polishing method is proposed. By studying the mechanism of polishing, and provide a theoretical basis for the polishing process. Experimental results show that the use of swirl-type rolling polishing method, when the revolution speed N=72r/min and rotation speed n=108r/min, in 30-40min, the hub surface was polished and obtained the roughness value of Ra0.5μm in resin blocks containing silica powder.Based on the above studied, a complete set large surface mechanical polishing process is proposed, the single-station, multi-abrasive linkage mechanical polishing in the non-free abrasive class and the swirl-type rolling polishing in the free abrasive class were integrated. Compared with the manual polishing, in the premise to obtain stable polished surface quality, polishing efficiency has been increased by 70%, and than other single-abrasive mechanical polishing methods also have quality and efficiency advantages. In addition, the use of complete sets of mechanical polishing equipment, but also for enterprises to enhance their image, reducing pollution, improving the working environment of workers, reduce dependence on skilled workers and so on, play an important economic and social effects.