The Design And Research Of 3D Magnetorheological Polishing Machine

With the rapid development of modern science and technology and people's continuous pursuit of high-quality products,optical communications,medical equipment,civil and other fields have increasingly high requirements for components.Components should be designed to meet both functional requirements and high standards of appearance,such as irregular outer surfaces,3D curved surfaces and so on.Components requires not only high surface accuracy,small surface roughness and small subsurface failure layer,but also high processing efficiency and low cost.The advantages and disadvantages of the several precision and ultra-precision processing methods are analyzed,and the advantages of magnetorheological polishing method are proposed.This thesis with the magnetorheological polishing device of a domestic manufacturer as the research background aims to research and design a high efficiency precision polishing equipment,which can deal with flat,convex,concave,and other highly irregular surface of nonmagnetic materials such as stainless steel,glass,sapphire,magnesium,ceramic.Thesis mainly includes three parts: the mechanical structure design,magnetic field generator and digital control system.The main works of the thesis are as follows:1.A low cost and high efficiency magnetorheological polishingmethod is researched.The plane and surface polishing motion are analyzed.According to the polishing removal mechanism and functional requirements,the general scheme of magnetorheological polishing machine is determined,in which the mechanical transmission system of magnetorheological polishing machine is composed of the revolution rotation system and the rotation transmission system,which can finish the efficient polishing of plane and surface.In order to ensure the rationality of structural design,finite element simulation is carried out on the key parts.2.Based on three-dimensional static magnetic field finite element analysis,the magnetic field generator of magnetorheological polishing machine is optimized and simulated.According to the requirement of polishing,circular array,fan and ring magnetic field generator are designed,and Ansoft Maxwell finite element simulation is used to comprehensively analyze the variation trend of magnetic field intensity cloud,magnetic field direction and 5mm high magnetic field curve to determine the optimal magnetic circuit structure.In addition,considering that the magnetic field coil will generate a lot of heat when it is energized for a long time,it is not enough to rely only on natural cooling.Based on the magnetic field structure design,a suitable cooling design scheme is analyzed and selected.3.The digital control system of polishing machine based on timefactors integrates mechanical transmission,real-time monitoring,magnetorheological fluid circulation,temperature control,etc.The digital control system adopts HMI human-machine interface parameterized cooperative control,which can not only control the rotation speed,revolution speed,swing angle and magnetic field intensity to achieve the best polishing effect,but also monitor the magnetic field temperature,magnetorheological fluid temperature,machine tool load,magnetorheological fluid life and realize the recycling of magnetorheological fluid.The paper summarizes the function of manual interface and automatic interface in detail.4.The magnetorheological polishing machine is developed and debugged.Appropriate experimental methods are selected to conduct polishing experiments on multiple samples,and the experimental results are analyzed to further demonstrate the feasibility of the design.