Surface Grinding Quality of Stainless Steel by Different Magnetic Composite Particle Preparation Parameters AITranslate

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Basic Information:

DOI：10.13373/j.cnki.cjrm.XY24020006

Chinese Library Classification Number:TG580

Citation Information:

The magnetic field-assisted grinding (MFAG) method is a novel ultra-precision surface machining technology. In this paper, a new magnetic abrasive particle with high efficiency and low cost was prepared by the bonding method to improve the uniformity of the iron-based phase and grinding phase for the ultra-precision grinding of 304 stainless steel efficiently. The effects of different component ratios on the abrasive properties of magnetic abrasive particles prepared by the bonding method were investigated. The surface morphology of magnetic abrasive particles and workpieces before and after grinding was observed by ultra-depth three-dimensional microscope and white light interferometer, and the surface quality of workpieces before and after grinding was compared by surface roughness measuring instrument, the excellent proportioning of magnetic abrasive particles by bonding method was finally determined. Two kinds of magnetic abrasive particles were prepared by different processes of bonding method and traditional mechanical mixing method, in addition, the grinding properties were investigated experimentally. The results showed that the initial surface was smoothed after grinding. In addition, the grinding marks were observed, regardless of the mass ratio of iron base phase to grinding phase (3∶1, 4∶1 and 5∶1) used in the grinding process. When the mass ratio of iron base phase to grinding phase was 4∶1, the surface roughness (R_a) decreased from 206 to 49 nm after 9 min grinding, meaning the decrease rate of surface roughness was 76.2% due to the appropriate saturation magnetization. The grinding force was 1.2, 1.6 and 2.4 N, respectively, when the mass ratio of iron base phase to grinding phase was 3∶1, 4∶1 and 5∶1. Once the mass of the iron-base phase was higher, the grinding force increased sharply, resulting in deeper scratches. The mass ratio of the adhesive and curing agent was an important parameter affecting the surface roughness in the MFAG process. The surface roughness decreased first with the increase in additive E-44 epoxy resin, then increased when the mass ratio was more than 40%. It could be observed from the ground abrasive particles that the area of the grinding phase decreased from 80.5% before grinding to 32.6% after grinding with MAP-1 grinding, which was composed of organic silicon resin and curing agent. Due to the addition of E-44 epoxy resin, the toughness of the adhesive was improved, and the impact strength was enhanced. The surface quality of 304 stainless steel was improved after grinding with different ratios of iron matrix to abrasive phase particle size. However, the decreasing trend of surface roughness R_a was not the same. A continuous decrease in surface roughness R_a with increasing of grinding time, but the rate of decline was relatively slow using MAP-d_2-1 (the ratio was 2∶1）. After grinding with MAP-d_3-1 for 9 min, the smoothest surface could be obtained. Subsequently, the surface quality deteriorated, resulting in the fastest decrease rate in surface roughness in the first 3 min using MAP-d_4-1；afterwards, it slowly dropped to its lowest point in the following 6 min. The grinding force was 0.5, 1.6 and 2.0 N, respectively, when the saturation magnetization was 133.3, 149 and 151.9 emu·g⁻¹. During the grinding process, a larger diameter iron powder should be selected first to remove the original defects on the surface of the workpiece. Then, the smaller diameter iron powder should be chosen to achieve lower surface roughness. The influence of different ratios of mixture to binder on surface roughness was finally studied. The lack of binders (the ratio was 10∶0.8) led to a lower bonding strength of the grinding phase, resulting in a few grinding phases participating in the grinding process, leading to lower grinding efficiency. On the contrary, some of the abrasive particles were wrapped entirely by the excessive adhesive (the ratio was 10∶1.2）, reducing the number of cutting edges involved in the grinding process and decreasing grinding efficiency. When the ratio of the mixture to the binder was 10∶1, the surface of the iron substrate was uniformly covered with the grinding phase, which showed excellent grinding effects. To summarize, when the mass ratio of iron base phase to grinding phase was 4∶1, the particle size ratio was 3∶1, the mass ratio of the mixture of iron matrix and grinding phase to binder was 10∶1, and the mass ratio of E-44 epoxy resin, silicone resin to polyamide curing agent was 4∶1∶5, the grinding effect of magnetic abrasive particles was the best. The experimental results showed that the bonding method was superior to the traditional mechanical mixing method regarding grinding efficiency and workpiece surface machining accuracy. After grinding with this magnetic abrasive particle for 9 min, the surface roughness R_a of the workpiece was reduced from the original of 206 nm to 49 nm. The surface quality of the workpiece was improved. The white corundum/ferromagnetic abrasive prepared by the bonding method could achieve high efficiency and high-quality grinding of 304 stainless steel.