基于注塑模具鋼研磨和拋光工序的自動(dòng)化表面處理外文文獻(xiàn)翻譯、中英文翻譯

1、XXXXXXXX設(shè)計(jì)(XX)外文資料翻譯系部： 專 業(yè)： 姓 名： 學(xué) 號(hào)： 外文出處：Automated surface finishing of plastic injection mold steel with spherical grinding ang ball burnishing processess 附 件： 1.外文資料譯文；2.外文原文。 指導(dǎo)教師評(píng)語(yǔ)：譯文基本能表達(dá)原文思想，語(yǔ)句較流暢，條理較清晰，專業(yè)用語(yǔ)翻譯基本準(zhǔn)確，基本符合中文習(xí)慣，整體翻譯質(zhì)量一般。 簽名： 20XX年 3 月 19 日附件1：外文資料翻譯譯文基于注塑模具鋼研磨和拋光工序的自動(dòng)化表面處理摘要 本文研

2、究了注塑模具鋼自動(dòng)研磨與球面拋光加工工序的可能性，這種注塑模具鋼P(yáng)DS5的塑性曲面是在數(shù)控加工中心完成的。這項(xiàng)研究已經(jīng)完成了磨削刀架的設(shè)計(jì)與制造。 最佳表面研磨參數(shù)是在鋼鐵PDS5 的加工中心測(cè)定的。對(duì)于PDS5注塑模具鋼的最佳球面研磨參數(shù)是以下一系列的組合：研磨材料的磨料為粉紅氧化鋁，進(jìn)給量500毫米/分鐘，磨削深度20微米，磨削轉(zhuǎn)速為18000RPM。用優(yōu)化的參數(shù)進(jìn)行表面研磨，表面粗糙度Ra值可由大約1.60微米改善至0.35微米。 用球拋光工藝和參數(shù)優(yōu)化拋光，可以進(jìn)一步改善表面粗糙度Ra值從0.343微米至0.06微米左右。在模具內(nèi)部曲面的測(cè)試部分，用最佳參數(shù)的表面研磨、拋光，曲面表面粗

3、糙度就可以提高約2.15微米到0.007微米。關(guān)鍵詞 自動(dòng)化表面處理 拋光 磨削加工 表面粗糙度 田口方法 一、引言 塑膠工程材料由于其重要特點(diǎn),如耐化學(xué)腐蝕性、低密度、易于制造,并已日漸取代金屬部件在工業(yè)中廣泛應(yīng)用。 注塑成型對(duì)于塑料制品是一個(gè)重要工藝。注塑模具的表面質(zhì)量是設(shè)計(jì)的本質(zhì)要求,因?yàn)樗苯佑绊懥怂苣z產(chǎn)品的外觀和性能。 加工工藝如球面研磨、拋光常用于改善表面光潔度。研磨工具(輪子)的安裝已廣泛用于傳統(tǒng)模具的制造產(chǎn)業(yè)。自動(dòng)化表面研磨加工工具的幾何模型將在下面介紹。自動(dòng)化表面處理的球磨研磨工具將從中得到示范和開發(fā)。 磨削速度, 磨削深度，進(jìn)給速率和砂輪尺寸、研磨材料特性（如磨料粒度大?。?/p>

4、是球形研磨工藝中主要的參數(shù)。注塑模具鋼的球面研磨最優(yōu)化參數(shù)目前尚未在文獻(xiàn)得到確切的依據(jù)。 近年來(lái) ，已經(jīng)進(jìn)行了一些研究，確定了球面拋光工藝的最優(yōu)參數(shù)。 比如，人們發(fā)現(xiàn), 用碳化鎢球滾壓的方法可以使工件表面的塑性變形減少,從而改善表面粗糙度、表面硬度、抗疲勞強(qiáng)度。 拋光的工藝的過(guò)程是由加工中心 3,4和車床5,6共同完成的。對(duì)表面粗糙度有重大影響的拋光工藝主要參數(shù)，主要是球或滾子材料，拋光力， 進(jìn)給速率,拋光速度,潤(rùn)滑、拋光率及其他因素等。注塑模具鋼P(yáng)DS5的表面拋光的參數(shù)優(yōu)化，分別結(jié)合了油脂潤(rùn)滑劑，碳化鎢球,拋光速度200毫米/分鐘,拋光力300牛， 40微米的進(jìn)給量。采用最佳參數(shù)進(jìn)行表面研磨

5、和球面拋光的深度為2.5微米。通過(guò)拋光工藝，表面粗糙度可以改善大致為40%至90%。 此項(xiàng)目研究的目的是，發(fā)展注塑模具鋼的球形研磨和球面拋光工序，這種注塑模具鋼的曲面實(shí)在加工中心完成的。表面光潔度的球研磨與球拋光的自動(dòng)化流程工序。 我們開始自行設(shè)計(jì)和制造的球面研磨工具及加工中心的對(duì)刀裝置。利用田口正交法，確定了表面球研磨最佳參數(shù)。選擇為田口L18型矩陣實(shí)驗(yàn)相應(yīng)的四個(gè)因素和三個(gè)層次。 用最佳參數(shù)進(jìn)行表面球研磨則適用于一個(gè)曲面表面光潔度要求較高的注塑模具。 為了改善表面粗糙, 利用最佳球面拋光工藝參數(shù)，再進(jìn)行對(duì)表層打磨。二、球研磨的設(shè)計(jì)和對(duì)準(zhǔn)裝置實(shí)施過(guò)程中可能出現(xiàn)的曲面的球研磨,研磨球的中心應(yīng)和加

6、工中心的Z軸相一致。 球面研磨工具的安裝及調(diào)整裝置的設(shè)計(jì)。電動(dòng)磨床展開了兩個(gè)具有可調(diào)支撐螺絲的刀架。磨床中心正好與具有輔助作用的圓錐槽線配合。 擁有磨床的球接軌,當(dāng)兩個(gè)可調(diào)支撐螺絲被收緊時(shí)，其后的對(duì)準(zhǔn)部件就可以拆除。研磨球中心坐標(biāo)偏差約為5微米, 這是衡量一個(gè)數(shù)控坐標(biāo)測(cè)量機(jī)性能的重要標(biāo)準(zhǔn)。 機(jī)床的機(jī)械振動(dòng)力是被螺旋彈簧所吸收。球形研磨球和拋光工具的安裝。為使球面磨削加工和拋光加工的進(jìn)行，主軸通過(guò)球鎖機(jī)制而被鎖定。 三、矩陣實(shí)驗(yàn)的規(guī)劃3.1田口正交表:利用矩陣實(shí)驗(yàn)田口正交法，可以確定參數(shù)的有影響程度. 為了配合上述球面研磨參數(shù)，該材料磨料的研磨球(直徑10毫米),進(jìn)給速率，研磨深度,在次研究中電

7、氣磨床被假定為四個(gè)因素(參數(shù))，指定為從A到D。三個(gè)層次(程度)的因素涵蓋了不同的范圍特征,并用了數(shù)字1、2、3標(biāo)明。挑選三類磨料,即碳化硅(SiC),白色氧化鋁(Al2O3,WA),粉紅氧化鋁(Al2O3, PA)來(lái)研究. 這三個(gè)數(shù)值的大小取決于每個(gè)因素實(shí)驗(yàn)結(jié)果。選定L18型正交矩陣進(jìn)行實(shí)驗(yàn)，進(jìn)而研究四三級(jí)因素的球形研磨過(guò)程。3.2數(shù)據(jù)分析的界定: 工程設(shè)計(jì)問題,可以分為較小而好的類型,象征性最好類型,大而好類型，目標(biāo)取向類型等。 信噪比(S/N)的比值，常作為目標(biāo)函數(shù)來(lái)優(yōu)化產(chǎn)品或者工藝設(shè)計(jì)。 被加工面的表面粗糙度值經(jīng)過(guò)適當(dāng)?shù)亟M合磨削參數(shù)，應(yīng)小于原來(lái)的未加工表面。 因此,球面研磨過(guò)程屬于工程

8、問題中的小而好類型。從每個(gè)L18型正交實(shí)驗(yàn)得到的信噪比（S/N）數(shù)據(jù)，經(jīng)計(jì)算后，運(yùn)用差異分析技術(shù)(變異)和殲比檢驗(yàn)來(lái)測(cè)定每一個(gè)主要的因素。 優(yōu)化小而好類型的工程問題問題更是盡量使最大而定。各級(jí)選擇的最大化將對(duì)最終的因素有重大影響。 最優(yōu)條件可視研磨球而待定。 四、實(shí)驗(yàn)工作和結(jié)果: 這項(xiàng)研究使用的材料是PDS5工具鋼(相當(dāng)于艾西塑膠模具)， 它常用于大型注塑模具產(chǎn)品在國(guó)內(nèi)汽車零件領(lǐng)域和國(guó)內(nèi)設(shè)備。 該材料的硬度約HRC33(HS46)。 具體好處之一是, 由于其特殊的熱處理前處理，模具可直接用于未經(jīng)進(jìn)一步加工工序而對(duì)這一材料進(jìn)行加工。式樣的設(shè)計(jì)和制造,應(yīng)使它們可以安裝在底盤，來(lái)測(cè)量相應(yīng)的反力。 P

9、DS5試樣的加工完畢后，裝在大底盤上在三坐標(biāo)加工中心進(jìn)行了銑削，這種加工中心是由楊*鋼鐵公司所生產(chǎn)(中壓型三號(hào)),配備了FANUC-18M公司的數(shù)控控制器(0.99型)。用hommelwerket4000設(shè)備來(lái)測(cè)量前機(jī)加工前表面的粗糙度,使其可達(dá)到1.6微米。 一個(gè)由Renishaw公司生產(chǎn)的視頻觸摸觸發(fā)探頭，安裝在加工中心上，來(lái)測(cè)量和確定和原始式樣的協(xié)調(diào)。 數(shù)控代碼所需要的磨球路徑由PowerMILL軟件產(chǎn)。這些代碼經(jīng)過(guò)RS232串口界面，可以傳送到裝有控制器的數(shù)控加工中心上。球面研磨工藝的目標(biāo)，就是通過(guò)確定每一種因子的最佳優(yōu)化程度值，來(lái)使試樣光滑表層的表面粗糙度值達(dá)到最小。因?yàn)?log是一

10、個(gè)減函數(shù)，我們應(yīng)當(dāng)使信噪比（S/N）達(dá)到最大。因此，我們能夠確定每一種因子的最優(yōu)程度使得的值達(dá)到最大。因此基于這個(gè)點(diǎn)陣式實(shí)驗(yàn)的最優(yōu)轉(zhuǎn)速應(yīng)該是18000RPM通過(guò)使用數(shù)據(jù)方差分析的技術(shù)和F比檢驗(yàn)方法，進(jìn)一步確定了每一種因子有什么主要的影響，從而確定了它們的影響程度。F0.1，2，13的F比的比值是2.76，相當(dāng)于10%的影響程度。（或者置信水平為90%）這個(gè)因子的自由度是2，自由度誤差是13。如果F比值大于2.76，就可以認(rèn)為對(duì)表面粗糙度有顯著影響。結(jié)果，進(jìn)給量和磨削深度都對(duì)表面粗糙度有顯著影響。為了觀察使用最優(yōu)磨削組合參數(shù)的重復(fù)性能，進(jìn)行了5種不同類別的實(shí)驗(yàn)，如表6所示。獲得被測(cè)試樣的表面粗糙

11、度值RA大約是0.35微米。使用球研磨組合參數(shù)，可使表面粗糙度提高了78%。使用球面拋光的優(yōu)化參數(shù)，光滑表面進(jìn)一步被拋光。經(jīng)過(guò)球面拋光可獲得粗糙度RA值為0.06微米的表面。被改善了的拋光表面，可以在30光學(xué)顯微鏡觀察下進(jìn)行觀察。經(jīng)過(guò)拋光工藝，工件機(jī)加工前的表面粗糙度改善了近95%。從田口矩陣實(shí)驗(yàn)獲得的球面研磨優(yōu)化參數(shù)，適用于曲面光滑的模具，從而改善表面的粗糙度。選擇香水瓶為一個(gè)測(cè)試載體。對(duì)于被測(cè)物體的模具數(shù)控加工中心，由PowerMILL軟件來(lái)模擬測(cè)試。經(jīng)過(guò)精銑，通過(guò)使用從田口矩陣實(shí)驗(yàn)獲得的球面研磨優(yōu)化參數(shù)，模具表面進(jìn)一步光滑。緊接著,使用打磨拋光的最佳參數(shù)，來(lái)對(duì)光滑曲面進(jìn)行拋光工藝，進(jìn)一步

12、改善了被測(cè)物體的表面粗糙度。模具內(nèi)部的表面粗糙度用hommelwerket4000設(shè)備來(lái)測(cè)量。模具內(nèi)部的表面粗糙度RA的平均值為2.15微米，光滑表面粗糙度RA的平均值為0.45微米，拋光表面粗糙度RA的平均值為0.07微米。被測(cè)物體的光滑表面的粗糙度改善了：(2.15-0.45)/2.15=79.1%，拋光表面的粗糙度改善了：(2.15-0.07)/2.15=96.7%。五、結(jié)論:在這項(xiàng)工作中,對(duì)注塑模具的曲面進(jìn)行了自動(dòng)球面研磨與球面拋光加工，并將其工藝最佳參數(shù)成功地運(yùn)用到加工中心上。 設(shè)計(jì)和制造了球面研磨裝置(及其對(duì)準(zhǔn)組件)。通過(guò)實(shí)施田口L18型矩陣進(jìn)行實(shí)驗(yàn)，確定了球面研磨的最佳參數(shù)。對(duì)于

13、PDS5注塑模具鋼的最佳球面研磨參數(shù)是以下一系列的組合：材料的磨料為粉紅氧化鋁，進(jìn)給量料500毫米/分鐘，磨削深度20微米，轉(zhuǎn)速為18000RPM。通過(guò)使用最佳球面研磨參數(shù)，試樣的表面粗糙度RA值從約1.6微米提高到0.35微米。應(yīng)用最優(yōu)化表面磨削參數(shù)和最佳拋光參數(shù)，來(lái)加工模具的內(nèi)部光滑曲面，可使模具內(nèi)部的光滑表面改善79.1%，拋光表面改善96.7%。參考文獻(xiàn)1 Loh NH ，Tam SC,Miyazawa S(1991)表面被球擦光加工時(shí)產(chǎn)生粗糙的調(diào)查。2 Phadke 小姐 (1989) 質(zhì)量工程學(xué)使用健康的設(shè)計(jì)。3 Ta-Tung 公司塑料注射模技術(shù)手冊(cè)。4 楊鐵工廠 (1996)

14、MV-3A 垂直機(jī)制技術(shù)手冊(cè)。附件2：外文原文（復(fù)印件）Automated surface finishing of plastic injection mold steelwith spherical grinding and ball burnishing processesReceived: 30 March 2004 / Accepted: 5 July 2004 / Published online: 30 March 2005. Springer-Verlag London Limited 2005Abstract This study investigates the possi

15、bilities of automated spherical grinding and ball burnishing surface finishing processes in a freeform surface plastic injection mold steel PDS5 on a CNC machining center. The design and manufacture ofa grinding tool holder has been accomplished in this study.The optimal surface grinding parameters

16、were determined using Taguchis orthogonal array method for plastic injection molding steel PDS5 on a machining center. The optimal surface grinding parameters for the plastic injection mold steel PDS5 were the combination of an abrasive material of PA Al2O3, a grinding speed of 18 000 rpm, a grindin

17、g depth of 20 m, and a feed of 50 mm/min. The surface roughness Ra of the specimen can be improved from about 1.60 m to 0.35 m by using the optimal parameters for surface grinding. Surface roughness Ra can be further improved from about 0.343 m to 0.06 m by using the ball burnishing process with the

18、 optimal burnishing parameters. Applying the optimal surface grinding and burnishing parameterssequentially to a fine-milled freeform surface mold insert, the surface roughnessRa of freeform surface region on the tested part can be improved from about 2.15 m to 0.07 m.Keywords Automated surface fini

19、shing Ballburnishing process Grinding process Surface roughness Taguchis method1 IntroductionPlastics are important engineering materials due to their specific characteristics, such as corrosion resistance, resistance to chemicals,low density, and ease of manufacture, and have increasingly replaced

20、metallic components in industrial applications. Injection molding is one of the important forming processes for plastic products. The surface finish quality of the plastic injection mold is an essential requirement due to its direct effects on the appearance of the plastic product. Finishing process

21、es such as grinding, polishing and lapping are commonly used to improve the surface finish. The mounted grinding tools (wheels) have been widely used in conventional mold and die finishing industries. The geometric model of mounted grinding tools for automated surface finishing processes was introdu

22、ced in 1. A finishing process model of spherical grinding tools for automated surface finishing systems was developed in 2. Grinding speed, depth of cut, feed rate, and wheel properties such as abrasive material and abrasive grain size, are the dominant parameters for the spherical grinding process.

23、The optimal spherical grinding parameters for the injection mold steel have not yet been investigatedbased in the literature.In recent years, some research has been carried out in determining the optimal parameters of the ball burnishing process.For instance, it has been found that plastic deformati

24、on on the workpiece surface can be reduced by using a tungsten carbide ball or a roller, thus improving the surface roughness, surface hardness, and fatigue resistance 36. The burnishing process is accomplished by machining centers 3, 4 and lathes 5, 6. The main burnishing parameters having signific

25、anteffects on the surface roughness are ball or roller material, burnishing force, feed rate, burnishing speed, lubrication, and number of burnishing passes, among others 3. The optimal surface burnishing parameters for the plastic injection mold steelPDS5 were a combination of grease lubricant, the

26、 tungsten carbide ball, a burnishing speed of 200 mm/min, a burnishing force of 300 N, and a feed of 40 m 7. The depth of penetration of the burnished surface using the optimal ball burnishing parameterswas about 2.5 microns. The improvement of the surface roughness through burnishing process genera

27、lly ranged between 40% and 90% 37. The aim of this study was to develop spherical grinding and ball burnishing surface finish processes of a freeform surface 62 plastic injection mold on a machining center. The flowchart ofautomated surface finish using spherical grinding and ball burnishing process

28、es is shown in Fig. 3. We began by designing and manufacturing the spherical grinding tool and its alignment device for use on a machining center. The optimal surface sphericalgrinding parameters were determined by utilizing a Taguchis orthogonal array method. Four factors and three corresponding le

29、vels were then chosen for the Taguchis L18 matrix experiment. The optimal mounted spherical grinding parameters for surface grinding were then applied to the surface finish of a freeformsurface carrier. To improve the surface roughness, the ground surface was further burnished, using the optimal bal

30、l burnishing parameters.2 Design of the spherical grinding tool and itsalignment deviceTo carry out the possible spherical grinding process of a freeform surface, the center of the ball grinder should coincide with the z-axis of the machining center. The mounted spherical grinding tool and its adjus

31、tment device was designed.The electric grinder was mounted in a tool holder with two adjustable pivot screws. The center of the grinder ball was well aligned with the help of the conic groove of the alignment components. Having aligned the grinder ball, two adjustable pivotscrews were tightened; aft

32、er which, the alignment components could be removed. The deviation between the center coordinates of the ball grinder and that of the shank was about 5 m, which was measured by a CNC coordinate measuring machine. The force induced by the vibration of the machine bed is absorbed by a helical spring.

33、The manufactured spherical grinding tool and ball-burnishing tool were mounted. The spindle was locked for both the spherical grinding process and the ball burnishing process by a spindle-locking mechanism.3 Planning of the matrix experiment3.1 Configuration of Taguchis orthogonal array The effects

34、of several parameters can be determined efficiently by conducting matrix experiments using Taguchis orthogonalarray 8. To match the aforementioned spherical grinding parameters,the abrasive material of the grinder ball (with the diameter of 10 mm), the feed rate, the depth of grinding, and the revol

35、ution of the electric grinder were selected as the four experimental factors (parameters) and designated as factor A to D (seeTable 1) in this research. Three levels (settings) for each factor were configured to cover the range of interest, and were identi- fied by the digits 1, 2, and 3. Three type

36、s of abrasive materials, namely silicon carbide (SiC), white aluminum oxide (Al2O3,WA), and pink aluminum oxide (Al2O3, PA), were selected and studied. Three numerical values of each factor were determined based on the pre-study results. The L18 orthogonal array was selected to conduct the matrix ex

37、periment for four 3-level factors of the spherical grinding process. 3.2 Definition of the data analysis Engineering design problems can be divided into smaller-thebettertypes, nominal-the-best types, larger-the-better types, signed-target types, among others 8. The signal-to-noise (S/N) ratio is us

38、ed as the objective function for optimizing a product or process design. The surface roughness value of the ground surfacevia an adequate combination of grinding parameters should be smaller than that of the original surface. Consequently, the spherical grinding process is an example of a smaller-th

39、e-better type problem. The S/N ratio, , is defined by the followingequation.After the S/N ratio from the experimental data of each L18 orthogonal array is calculated, the main effect of each factor was determined by using an analysis of variance (ANOVA) technique and an F-ratio test 8. The optimizat

40、ion strategy of smaller-the better problem is to maximize , as defined by Eq. 1.Levels that maximize will be selected for the factors that have a significant effect on . The optimal conditions for spherical grinding can then be determined.4 Experimental work and resultsThe material used in this stud

41、y was PDS5 tool steel (equivalent to AISI P20) 9, which is commonly used for the molds of large plastic injection products in the field of automobile components and domestic appliances. The hardness of this materialis about HRC33 (HS46) 9. One specific advantage of this material is that after machin

42、ing, the mold can be directly used for further finishing processes without heat treatment due to its special pre-treatment. The specimens were designed and manufactured so that they could be mounted on a dynamometer to measure the reaction force. The PDS5 specimen was roughly machined and then mount

43、ed on the dynamometer to carry out the fine milling on a three-axis machining center made by Yang-Iron Company (type MV-3A), equipped with a FUNUC Company NC-controller (type 0M) 10. The pre-machined surface roughness was measured, using Hommelwerke T4000 equipment,to be about 1.6 m. A MP10 touch-tr

44、igger probe made by the Renishaw Company was also integrated withthe machining center tool magazine to measure and determine the coordinated origin of the specimen to be ground. The NC codes needed for the ball-burnishing path were generated by PowerMILL CAM software. These codes can be transmitted

45、to the CNC controller of the machining center via RS232 serial interface.The goal in the spherical grinding process is to minimize the surface roughness value of the ground specimen by determining the optimal level of each factor. Since log is a monotone decreasing function, we should maximize the S

46、/N ratio. Consequently, we can determine the optimal level for each factor as being the level that has the highest value of . on the matrix experiment, the optimal abrasive material was pink aluminum oxide; the optimal feed was 50 mm/min; the optimaldepth of grinding was 20 m; and the optimal revolu

47、tion was 18 000 rpm, as shown in Table 4.The main effect of each factor was further determined by using an analysis of variance (ANOVA) technique and an F ratio test in order to determine their significance. The F0.10,2,13 is 2.76 for a level of significance equal to 0.10 (or90% confidence level); t

48、he factors degree of freedom is 2 and the degree of freedom for the pooled error is 13. An F ratio value greater than 2.76 can be concluded as having a significant effect on surface roughness and is identified by an asterisk. As a result, the feed and the depth of grinding have a significant effect

49、on surface roughness.Five verification experiments were carried out to observe the repeatability of using the optimal combination of grinding parameters. The obtainable surface roughness value Ra of such specimen was measured to be about 0.35 m.Surface roughness was improved by about 78% in using th

50、e op-timal combination of spherical grinding parameters. The ground surface was further burnished using the optimal ball burnishing parameters. A surface roughness value of Ra = 0.06 m was obtainable after ball burnishing. Improvement of the burnished surfaceroughness observed with a 30 optical micr

51、oscope . The improvement of pre-machined surfaces roughness was about 95% after the burnishing process. The optimal parameters for surface spherical grinding obtained from the Taguchis matrix experiments were applied to the surface finish of the freeform surface mold insert to evaluate the surface r

52、oughness improvement. A perfume bottle was selected as the tested carrier. The CNCmachining of the mold insert for the tested object was simulated with PowerMILL CAM software. After fine milling, the mold insert was further ground with the optimal spherical grinding parameters obtained fromthe Taguc

53、his matrix experiment. Shortly afterwards, the ground surface was burnished with the optimal ball burnishing parameters to further improve the surface roughness of the tested object. The surface roughness of the mold insert was measuredwith Hommelwerke T4000 equipment. The average surface roughness

54、value Ra on a fine-milled surface of the mold insert was 2.15 m on average; that on the ground surface was 0.45 m Comparison between the pre-machined surface, ground surface and the burnished surface of the tested specimen observed with a toolmakermicroscope (30)66 Fine-milled, ground and burnished mold insert of a perfume bottle on average; and that on burnished surface was 0.07 m on average.The surface roughness i