精密复杂形面电镀金刚石工具制造关键技术研究

发布时间：2018-10-31 08:57

【摘要】：金刚石是自然界中已知最硬的材料,具有强度高、耐磨性好和优异的物理化学性能,用金刚石作为切削材料制成的电镀金刚石工具性能优异,在光学玻璃、半导体、玉器、石材和硬脆难加工材料等方面性能尤为突出,被广泛应用于航空、航天、汽车、电子、陶瓷、建筑等领域,对工业的发展起着巨大的推动作用。随着电镀金刚石工具的应用,对其制造精度要求越来越高,国内在制造高精度电镀金刚石工具方面研究起步比较晚,对基础机理研究不够,精密复杂形面金刚石工具在制造精度和使用寿命方面存在着问题迫切需要解决,因此,开展对精密复杂形面电镀金刚石工具制造方法和制造工艺的研究对于提高高精度复杂形面电镀金刚石工具的制造水平,推动我国航空航天、汽车制造和磨削加工等相关领域的发展具有重要意义。本文对精密金刚石工具制造原理和各种制造方法进行了系统分析,设计了采用内镀法制造精密金刚石工具;并对内电镀法制造精度复杂形面金刚石工具主要工艺流程和精密上砂、镀层机械性能、镀层精度控制关键技术开展研究,以获得制造精密复杂形面金刚石工具的科学制造方法和工艺。具体研究工作如下:1.高精度金刚石工具的制造方法研究。通过对内镀法、外镀法和粉末冶金法制造金刚石工具的基本原理、工艺特点和应用场合进行系统分析,确定采用制造精度最高、形面复杂程度最大的内镀法来制造金刚石工具,并研究了内镀法制造精密金刚石工具的主要工艺流程和特点。2.内电镀法制造精密复杂形面金刚石工具的关键技术研究(1)内电镀精密上砂技术研究。通过对不同上砂方法对比分析,确定采用埋砂法来制造金刚石工具,并试验研究了阴极电流密度和上砂时间对上砂的影响规律。研究得到:以50/60粒度金刚石为例,阴极电流密度为0.5A/dm2,上砂时间为3小时,上砂较好。(2)镀液成分对镀层机械性能影响研究。利用正交试验的方法对镀液成分进行优化,分析镀液各成分对镀层性能的影响规律,采用极差法对试验结果进行处理得到:镀液成分中硫酸镍含量270g/L,硫酸钴20 g/L,氯化钠10g/L,硼酸(30g/L)时,镀层机械性能最好。(3)镀层内应力对金刚石工具精度影响研究。通过理论分析镀层内应力的产生机理和影响因素,并通过试验研究了主要影响因素对镀层精度的影响规律。研究结果表明:内应力随着电流密度的增大呈上升趋势;镀液中硫酸钴的含量在10g/L、镀液温度为50℃、添加剂糖精含量为1g/L时镀层内应力较小。3.项目制造的精密金刚石工具及精度。采用项目设计的内电镀制造方法制造金刚石工具,其精度测量得到:齿距误差±0.003mm;圆弧半径误差±0.01mm;工作型面轮廓误差0.005mm;径向尺寸误差±0.003mm;角度误差±5′;形状误差0.006mm;跳动误差0.004mm。
[Abstract]:Diamond is the hardest material known in nature, with high strength, good wear resistance and excellent physical and chemical properties. Electroplating diamond tools made of diamond as cutting material have excellent performance in optical glass, semiconductor, jade, etc. Stone and hard-brittle refractory materials are widely used in the fields of aviation, aerospace, automobile, electronics, ceramics, architecture and so on, which play a great role in promoting the development of industry. With the application of electroplated diamond tools, the manufacturing accuracy of electroplated diamond tools is becoming more and more high. There are some problems in manufacturing precision and service life of precision diamond tools with complex surface, which need to be solved urgently. The research on the manufacturing methods and manufacturing technology of precision and complex diamond electroplating tools can improve the manufacturing level of high precision and complex surface electroplating diamond tools and promote China's aerospace industry. The development of automobile manufacturing and grinding processing is of great significance. In this paper, the manufacturing principle and various manufacturing methods of precision diamond tools are systematically analyzed, and the precision diamond tools made by internal plating are designed. The main technological process and key technologies of precision sanding, coating mechanical properties and coating precision control are also studied. In order to obtain the scientific manufacturing method and technology of precision and complex diamond tools. The specific research work is as follows: 1. Research on Manufacturing method of High Precision Diamond tools. Based on the systematic analysis of the basic principle, technological characteristics and application situation of diamond tools made by internal plating, external plating and powder metallurgy, it is determined that the inner plating method with the highest manufacturing precision and the most complex profile is used to manufacture diamond tools. The main technological process and characteristics of precision diamond tools made by internal plating were also studied. 2. Research on the key Technology of making Precision complex Surface Diamond tools by Internal Electroplating (1) Research on Precision Sand filling in Internal Electroplating. Based on the comparative analysis of different sand feeding methods, it is determined that the sand burying method is used to make diamond tools, and the effect of cathode current density and sand loading time on sand surfacing is studied experimentally. The results show that: (2) the effect of bath composition on the mechanical properties of the coating is studied by taking 50 / 60 grain size diamond as an example, the cathodic current density is 0.5A / dm ~ (2), and the time of sanding is 3 hours. (2) the effect of bath composition on the mechanical properties of the coating is studied. The composition of the plating solution was optimized by orthogonal test, and the influence of the composition of the bath on the coating performance was analyzed. The results were obtained by using the range method: the nickel sulfate content in the bath composition was 270 g / L, and the cobalt sulfate content was 20 g / L, and the results were as follows: cobalt sulfate 20 g / L, nickel sulfate 270 g / L and cobalt sulfate 20 g / L, respectively. When sodium chloride is 10 g / L, boric acid (30g/L), the mechanical properties of the coating are the best. (3) the effect of internal stress on the precision of diamond tools is studied. The mechanism and influencing factors of the internal stress of the coating are analyzed theoretically, and the influence law of the main influencing factors on the precision of the coating is studied through experiments. The results show that the internal stress increases with the increase of current density, and the internal stress of the coating is smaller when the content of cobalt sulfate is 10 g / L, the bath temperature is 50 鈩，

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