Optimization Design And Experimental Research Of Magnetic Honing System

With the development of science and technology and the progress of production, people put forward higher requirement of the surface quality on machine part, there is also true of the surface quality of stainless steel tube. Because the stainless steel has high strength, high toughness, diamagnetism, corrosion resistance, beautiful appearance, and so on, all of which are excellent properties, so it is widely used in many industrial fields. However, in the process of high temperature solution treatment, the surface of stainless steel easily formed a layer of oxide skin that has strong adhesion with substratum. Therefore, the appropriate methods are used to remove the surface oxide skin, and reduce the surface roughness value timely and effectively, which has important significance to carry out the next procedure successfully, prevent corrosion on the surface of pipes and prolong the life of the workpiece.Because of the large slenderness ratio, easy to produce vibration and thermal deformation during the processing, the machining of the long stainless steel tube surface is always a difficult problem in the actual production. After the research, we found that the magnetic honing technique can be used in the removal of the long stainless steel tube surface oxide skin, and it is also used in rough, finish machining of the long stainless steel tube surface; the technology which is fully integrated with the magnetic technology and honing technology is an emerging technology for processing the inner surface of stainless steel tube. Through the previous study, we found that using magnetic honing method can be very good to meet the cutting performance, and can effectively improve the surface quality, but it has poor machining stability. This topic is produced under the background of the magnetic honing system’s poor machining stability.This paper mainly focuses on several aspects, such as the theoretical basis of magnetic honing system, electromagnetic field analysis, temperature field analysis, optimization analysis and experimental verification of magnetic honing process, and the main contents are as follows:(1)Based on the electromagnetism, electromechanics, some theoretical knowledge of magnetic material and rotating magnetic field were introduced, which laid the foundation for the following analysis and discussion. Magnetic circuit and electric circuit of the system was analyzed according to the inherent characteristics of magnetic honing system, and the motion equation of the system was established. This can be helpful in understanding of the system’s physical model, and explain the relations and their significance of the system’s internal power factor angle, power factor angle and power angle, and moreover, different magnetic honing head impacted on the magnetic circuit were compared. Based on electromagnetic field theory, heat transfer theory, this paper introduced the theory of electromagnetic field and temperature field analysis and finite element method, and then determined the software used in the numerical calculation and the simulation method.(2)By means of electromagnetic field finite element analysis software Ansoft, several different types of magnetic honing head were analyzed on two-dimensional no-load analysis, load analysis and temperature field analysis. From the magnetic induction intensity at machined surface, the number of each permanent magnet, maximum torque, the electromagnetic torque and speed stability after the system was stable, time reached thermal equilibrium and the maximum temperature, the optimum structure of the magnetic honing head suitable for magnetic honing was obtained.(3)Using the optimization design function of ANSYS Workbench,magnetic honing head weight, maximum temperature rise, electromagnetic torque optimal are regarded as the target of optimization analysis, and finally the optimum dimension parameters of the magnetic circuit structural’s magnetic honing were obtained, which laid a substantial foundation for the next step for better design magnetic honing head.(4)The optimized magnetic honing system were analyzed as three-dimensional electromagnetic field analysis and temperature field analysis, because of three-dimensional model closer to the actual model, it can reflect the performance of the system, so that it was more realistic to reflect performance of the system, and its highest temperature and electromagnetic torque met the processing stability by verification.(5)According to machining experiments of magnetic honing system, it were confirmed that the magnetic honing technology could effectively remove inner surface oxide of long stainless steel tube and reduce roughness of the surface. Then, the existing second generation magnetic and three generation honing head were experimentized, and the temperature field distribution were measured and the processing stability were observed. Meanwhile, the result obtained from the experiments were compared to results of the finite element simulation, and it was found that both of the error were within the range of engineering error, which provide a powerful data support and technical basis for follow-up research and improvement of magnetic honing system.