Research On Integrated Control Of Electrochemical Grinding Of Friction Pairs Surface And Its Process

Friction pairs widely exist in mechanical systems, and their tribological behavior will affect thework performance, service life and energy consumption of the mechanical systems. Because of meritswith high processing quality and efficiency, no grinding burrs, cracks, burns, small macroscopic forceand wheel wear and etc, electrochemical grinding is particularly suitable for processing the surface offriction pairs without complex texture. But there are too many parameters in the ECG, the influencelaw of machining quality is complex, and it is difficult to stably control machining accuracy andsurface quality, which restrict the application of ECG in the industrial production.Based on the study of ECG of surfaces of razor friction pairs, this paper develops an integratedcontrol system, investigates the influences of various parameters on machining quality. The primaryresearch contents of this paper including:1. To achieve accurate and effective control of processing parameters, an integrated controlsystem is developed. Based on the process characteristics and performance indicators ofelectrochemical grinding, the function requirements of control system are analyzed and then theoverall plan of integrated control system is designed. On the basis of the overall plan, a hardwareplatform is built by using IPC control, which uses CNC system and data acquisition card as the core.The hardware types are selected and the circuits are designed for motion control system, electrolytecontrol system and power control system. The control circuits are designed and PLC programs forCNC system are compiled for achieving the integrated control of CNC motion, linked motion andprotection when using IPC. Besides, based on layered modular, the Visual Basic process interface isconducted, which achieves human-computer interaction, automatic control, monitoring and manyother functions.2. Under the machining influence analysis and the integrated control operation, experiments onECG of the inner surface of razor caps are carried out on the self-developed equipment. Using flowfield numerical analysis and experimental validation, the electrolyte flow rate distribution inprocessing areas is studied and the structure of grinding head is optimized. Using the grinding head, asingle factor comparison experiment is carried out, in which the impact of feed rate, peak voltage,duty cycle and electrolyte temperature on roughness and flatness is investigated. Besides, processparameters are optimized according to the analysis of impact of parameters and later tests to ensureprocessing quality and efficiency.3. The inner surfaces of razor caps with roughness Ra0.3~0.5μm and flatness less than10μm are steadily processed by employing the stable integrated control system and the reliable process,which meet the needs of small batch production.