| With the rapid development of light industry in recent years,the demand on bathroom hardware which industry as it’s a major branch,has been rising year by year.Polishing is an important surface processing method for bathroom hardware products which allow obtaining high-quality appearance of the workpiece surface by micro-removal.This can be achieved by flexible abrasive belts and nylon belts in multi-stage.The glossiness is a main index for appearance evaluation to measure the brightness of the object.Manual polishing is applied in most of the domestic bathroom hardware plants,which brings unstable quality,low efficiency and serious pollution.The typical part of the faucet elbow is chosen as research object.In order to obtain higher production efficiency and higher polishing quality,it is urgent to develop an automatic polishing equipment for bathroom hardware products and process guidance method based on glossiness.For a specific incident angle,the surface glossiness mainly depends on the surface topography.In order to establish the correlation between surface glossiness and micro topography,according to the basic principle of light reflection and the corresponding correction formula for metal surface,the model of glossiness is established based on the hypothesis of micro-plane for rough surface in order to simulate and predict the glossiness of the specific surface topography.Further,five topography parameters are selected to characterize the polished surface topography.The simulation model of surface with specific topography parameters is established based on the linear filtering method and the Johnson transform system.The glossiness of simulated surfaces with different topographical parameters are calculated with the glossiness model and compared to establish the correlation between the surface glossiness and topography.In order to further work out the correlation model between surface topography and polishing parameters,the evolution process of surface topography in multi-stage belt polishing is further studied.The digital simulation model of belt surface topography is formulated through characterization and distribution model of the abrasive.The contact condition during polishing process was analyzed,and the actual contact condition was established based on mechanical analysis and Hertz contact theory.The surface generation model in the multi-stage belt polishing is established by the kinematic analysis of the polishing mechanism and workpiece during the polishing process.The evolution regulation of the surface topography with polishing process parameters in multi-stage polishing is figured out by simulations and experiments.Based on the research on the relation between glossiness and surface topography and the generation mechanism of surface microscopic topography in multi-stage belt polishing,the polishing parameter conditions for high,medium,low glossiness are obtained.And the evolution regulation with polishing process parameters and the correlation between each process of glossiness are concluded with joint simulation of multiple models.Based on the ideal glossiness index,the process optimization is conducted.In addition,considering multiple constraint conditions in multi-stage polishing,the multi-stage polishing process is optimized,the optimized polishing parameters in multi-stage polishing for stainless steel elbow are obtained.Finally,in order to validate the multi-stage polishing process model and the optimazed process based on the ideal glossiness index,the belt polishing device is designed and the automatic polishing process is realized by the double manipulator.The polishing path can be generated according to the actual shape of the elbow pipe with the path generation algorithm developed.The process is simplified on the premise of quality,and the result of process optimization is verified by the multi-stage polishing experiment,the belt polishing process for elbow is finally realized,and an effective process guidance method is provided. |
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