模具專業(yè)畢業(yè)設(shè)計(jì)外文翻譯--基于注塑模具鋼研磨和拋光工序的自動(dòng)化表面處理 （英文）

1、DOI 10.1007/s00170-004-2328-8OR I GI NAL AR T I C LEInt J Adv Manuf Technol (2006) 28: 61–66Fang-Jung Shiou · Chao-Chang A. Chen · Wen-Tu LiAutomated surface finishing of plastic injection mold steel with spher

2、ical 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 possibilities of

3、 automated spherical grinding and ball burnishing surface finishing pro- cesses in a freeform surface plastic injection mold steel PDS5 on a CNC machining center. The design and manufacture of a grinding tool holder has

4、been accomplished in this study. The optimal surface grinding parameters were determined using Taguchi’s orthogonal array method for plastic injection molding steel PDS5 on a machining center. The optimal surface grind-

5、ing parameters for the plastic injection mold steel PDS5 were the combination of an abrasive material of PA Al2O3, a grind- ing speed of 18000 rpm, a grinding depth of 20 µm, and a feed of 50 mm/min. The surface rou

6、ghness Ra of the specimen can be improved from about 1.60 µm to 0.35 µm by using the optimal parameters for surface grinding. Surface roughness Ra can be further improved from about 0.343 µm to 0.06 µ

7、m by using the ball burnishing process with the optimal burnishing parameters. Applying the optimal surface grinding and burnishing parame- ters sequentially to a fine-milled freeform surface mold insert, the surface rou

8、ghness Ra of freeform surface region on the tested part can be improved from about 2.15 µm to 0.07 µm.Keywords Automated surface finishing · Ball burnishing process · Grinding process · Surface r

9、oughness · Taguchi’s method1 IntroductionPlastics are important engineering materials due to their specific characteristics, such as corrosion resistance, resistance to chemi- cals, low density, and ease of manufact

10、ure, and have increasinglyF.-J. Shiou (u) · C.-C.A. Chen · W.-T. Li Department of Mechanical Engineering, National Taiwan University of Science and Technology, No. 43, Section 4, Keelung Road, 106 Taipei, Taiwa

11、n R.O.C. E-mail: shiou@mail.ntust.edu.tw Tel.: +88-62-2737-6543 Fax: +88-62-2737-6460replaced metallic components in industrial applications. Injec- tion molding is one of the important forming processes for plas- tic pr

12、oducts. 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 processes such as grinding, polishing and lapping

13、 are commonly used to improve the surface finish.The mounted grinding tools (wheels) have been widely usedin conventional mold and die finishing industries. The geometric model of mounted grinding tools for automated sur

14、face finish- ing processes was introduced in [1]. A finishing process model of spherical grinding tools for automated surface finishing sys- tems was developed in [2]. Grinding speed, depth of cut, feed rate, and wheel p

15、roperties such as abrasive material and abrasive grain size, are the dominant parameters for the spherical grind- ing process, as shown in Fig. 1. The optimal spherical grinding parameters for the injection mold steel ha

16、ve not yet been investi- gated based in the literature.In recent years, some research has been carried out in de-termining the optimal parameters of the ball burnishing pro- cess (Fig. 2). For instance, it has been found

17、 that plastic de- formation 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 [3–6]. The burnishing proce

18、ss is accomplished by machining centers [3, 4] and lathes [5, 6]. The main burnishing parameters having signifi- cant effects on the surface roughness are ball or roller material, burnishing force, feed rate, burnishing

19、speed, lubrication, and number of burnishing passes, among others [3]. The optimal sur- face burnishing parameters for the plastic injection mold steel PDS5 were a combination of grease lubricant, the tungsten car- bide

20、ball, a burnishing speed of 200 mm/min, a burnishing force of 300 N, and a feed of 40 µm [7]. The depth of penetration of the burnished surface using the optimal ball burnishing parameters was about 2.5 microns. The

21、 improvement of the surface rough- ness through burnishing process generally ranged between 40% and 90% [3–7].The aim of this study was to develop spherical grinding andball burnishing surface finish processes of a freef

22、orm surface63Fig. 4. Schematic illustration of the spherical grinding tool and its adjust- ment device3 Planning of the matrix experiment3.1 Configuration of Taguchi’s orthogonal arrayThe effects of several parameters ca

23、n be determined efficiently by conducting matrix experiments using Taguchi’s orthogonal array [8]. To match the aforementioned spherical grinding pa- rameters, the abrasive material of the grinder ball (with the diam- et

24、er of 10 mm), the feed rate, the depth of grinding, and the revolution of the electric grinder were selected as the four experi- mental factors (parameters) and designated as factor A to D (see Table 1) in this research.

25、 Three levels (settings) for each factor were configured to cover the range of interest, and were identi-Fig. 5. a Photo of the spherical grinding tool b Photo of the ball burnishing toolTable 1. The experimental factors

26、 and their levelsFactor Level1 2 3A. Abrasive material SiC Al2O3, WA Al2O3, PAB. Feed (mm/min) 50 100 200C. Depth of grinding (µm) 20 50 80D. Revolution (rpm) 12000 18000 24000fied by the digits 1, 2, and 3. Three t

27、ypes 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 t

28、he pre-study results. The L18 orthogonal array was se- lected to conduct the matrix experiment for four 3-level factors of the spherical grinding process.3.2 Definition of the data analysisEngineering design problems can

29、 be divided into smaller-the- better types, nominal-the-best types, larger-the-better types, signed-target types, among others [8]. The signal-to-noise (S/N) ratio is used as the objective function for optimizing a produ

30、ct or process design. The surface roughness value of the ground sur- face via an adequate combination of grinding parameters should be smaller than that of the original surface. Consequently, the spherical grinding proce

31、ss is an example of a smaller-the-better type problem. The S/N ratio, η, is defined by the following equation [8]:η = ?10 log10(mean square quality characteristic)= ?10 log10?1nn ?i=1y2i?. (1)where:yi: observations of th

32、e quality characteristic under different noiseconditionsn: number of experimentAfter the S/N ratio from the experimental data of each L18orthogonal array is calculated, the main effect of each factor was determined by us