基于响应曲面法的成型CBN砂轮高频感应钎焊温度均匀性研究

李奇林; 王西超; 丁凯; 雷卫宁; 陈佳佳

doi:10.13224/j.cnki.jasp.20220041

基于响应曲面法的成型CBN砂轮高频感应钎焊温度均匀性研究

doi: 10.13224/j.cnki.jasp.20220041

1.
江苏理工学院机械工程学院，江苏常州 213001
2.
上海电机学院电气学院，上海 200240
3.
南京林业大学机械电子工程学院，南京 210010

基金项目:

国家自然科学基金 51905234

详细信息

作者简介:
李奇林（1984-），男，副教授、硕士生导师，博士，主要从事超硬磨料砂轮钎焊技术研究。

通讯作者:
王西超（1982-），男，讲师、硕士生导师，博士，主要从事人工智能与数学建模研究。E‑mail：wangxc@sdju.edu.cn

中图分类号: V263.1
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出版历程
- 收稿日期: 2022-01-23

Investigation of temperature uniformity of profiled CBN grinding wheel under high frequency induction brazing based on response surface methodology

1.
School of Mechanical Engineering， Jiangsu University of Technology，Changzhou Jiangsu 213001，China
2.
College of Electrical Engineering，Shanghai Dianji University，Shanghai 200240，China
3.
College of Mechanical and Electrical Engineering， Nanjing Forestry University，Nanjing 210010，China

摘要

摘要:
成型砂轮在高频感应钎焊过程中存在温度分布不均匀导致钎焊质量无法满足使用要求，这是长期困扰超硬磨料砂轮高频感应钎焊技术的难题。针对该问题，提出温度均匀性的表征方法，以温度均匀度和平均温度为响应值，基于有限元仿真数据获得了响应曲面法模型。基于该模型，采用方差分析成型砂轮感应钎焊温度均匀性的影响因素显著程度由大到小依次为加热间隙、感应电流、导磁体长度。以平均温度值和温度均匀度为优化目标，基于响应曲面法优化线圈结构和工艺参数，开展了感应加热试验，证明响应曲面法模型优化结果的误差在6.94%以内。高频感应钎焊的成型立方氮化硼（cubic boron nitride，CBN）砂轮宏观形貌显示，钎料在成型面各处铺展的一致性好，表明钎焊过程中在成型面的温度分布具有较好的均匀性。
- 温度均匀性 /
- 高频感应钎焊 /
- 成型CBN砂轮 /
- 响应曲面法 /
- 方差分析
Abstract:
During high frequency induction brazing of super abrasive grinding wheels，it was difficult to get a uniform temperature distribution on the grinding wheel surface，especially the profiled grinding wheel.For this problem，a characterization method of temperature uniformity was proposed.Response surface methodology model of temperature uniformity and average temperature was established based on the finite element method results.Based on this model，analysis of variance was conducted to investigate the influence factors on the temperature uniformity of profiled grinding wheel.It was found that the degrees of the influence on the temperature uniformity and average temperature from maximum to minimum were heating gap，induction current and length of magnetizer respectively.With the target of average temperature and temperature uniformity，the optimal parameters were obtained based on response surface methodology method.The experimental results verified that the error of the response surface methodology models was below 6.94%.Finally，high frequency induction brazing of profiled cubic boron nitride（CBN）grinding wheel was carried out with the optimal parameters.A consistent brazing surface with good spread ability was observed，indicating that good temperature uniformity on the profiled surface was obtained during induction brazing.
- temperature uniformity /
- high frequency induction brazing /
- profiled CBN grinding wheel /
- response surface methodology /
- analysis of variance
注释:

1) 秦理曼

HTML

图 1 燕尾槽成型砂轮基体尺寸示意图（单位：mm）

Figure 1. Geometry scheme of dovetail slot profiled grinding wheel matrix （unit：mm）

下载: 全尺寸图片幻灯片

图 3 成型面温度分析路径

Figure 3. Measured path for profiled surface temperature analysis

下载: 全尺寸图片幻灯片

图 4 感应电流和加热间隙对平均温度的交互作用

Figure 4. Interaction effect of induction current and heating gap on average temperature

下载: 全尺寸图片幻灯片

图 6 导磁体对温度场的影响

Figure 6. Effect of magnetizer on temperature field

下载: 全尺寸图片幻灯片

表 1 响应曲面法各因素与水平

Table 1. Factor and level values of RSM

水平	因素
水平	电流I/A	导磁体长度L/mm	加热间隙h/mm
-1	80	1	1
0	120	3.6	3
1	160	6.2	5

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表 2 各因素设计方案与仿真结果

Table 2. Design and simulation results of each factors

序号	I/A	L/mm	h/mm	$\bar{T}$ /°C	U/%
1	80	1	3	226.847	94.02
2	120	6.2	5	450.8	90.18
3	120	1	5	350	91.57
4	160	3.6	5	584.6	93.24
5	120	3.6	3	538.8	96.61
6	160	6.2	3	829.5	90.84
7	120	1	1	1 406.4	81.56
8	120	6.2	1	1 359.6	82.27
9	80	3.6	1	851	93.35
10	80	3.6	5	227.6	96.02
11	80	6.2	3	238.3	94.65
12	160	1	3	806.1	85.52
13	160	3.6	1	2 124.1	80.71

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表 3 平均温度的ANOVA结果

Table 3. ANOVA results of average temperature

项目	平方和	自由度	均方差	F值	P值
模型	3.95×10⁶	5	7.91×10⁵	200.84	<0.000 1
I	9.80×10⁵	1	9.80×10⁵	248.99	<0.000 1
L	986.86	1	986.86	0.250 6	0.626 5
h	2.13×10⁶	1	2.13×10⁶	540.99	<0.000 1
$I \cdot h$	2.10×10⁵	1	2.10×10⁵	53.29	<0.000 1
h²	6.33×10⁵	1	6.33×10⁵	160.69	<0.000 1
残差	43 312.39	11	3 937.49
失拟	43 312.39	7	6 187.48
纯误差	0	4	0
总计	4.00×10⁶	16		R²=0.982 9	R_adj²=0.984 2

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表 4 温度均匀度的ANOVA结果

Table 4. ANOVA results of temperature uniformity

项目	平方和	自由度	均方差	F值	P值
模型	497.462 9	7	71.066	95.951	<0.000 1
I	110.038 6	1	110.038	148.57	<0.000 1
L	3.591 2	1	3.591	4.848	0.055 1
h	137.697	1	137.697	185.914	<0.000 1
$I \cdot L$	4.730 6	1	4.73	6.387	0.032 3
$I \cdot h$	24.900 1	1	24.9	33.619	0.000 26
L²	93.797	1	93.797	126.641	<0.000 1
h²	110.717 1	1	110.717	149.486	<0.000 1
残差	6.665 8	9	0.741
失拟	6.665 8	5	1.333
纯误差	0	4	0
总计	504.128 8	16		R²=0.986 8	R_adj²=0.976 5

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