1、DOI10/1007/s00170-004-2328-8ORIGINALARTICLEIntJAdvManufTechnol(2006)28/6166Fang-JungShiouChao-ChangA/ChenWen-TuLiAutomatedsurfacefinishingofplasticinjectionmoldsteelwithsphericalgrindingandballburnishingprocessesReceived/30March2004/Accepted/5July2004/Publishedonline/30March2005Springer-VerlagLondon
2、Limited2005AbstractThisstudyinvestigatesthepossibilitiesofautomatedsphericalgrindingandballburnishingsurfacefinishingpro-cessesinafreeformsurfaceplasticinjectionmoldsteelPDS5onaCNCmachiningcenter/Thedesignandmanufactureofagrindingtoolholderhasbeenaccomplishedinthisstudy/Theoptimalsurfacegrindingpara
3、metersweredeterminedusingTaguchisorthogonalarraymethodforplasticinjectionmoldingsteelPDS5onamachiningcenter/Theoptimalsurfacegrind-ingparametersfortheplasticinjectionmoldsteelPDS5werethecombinationofanabrasivematerialofPAAl2O3/agrind-ingspeedof18000rpm/agrindingdepthof20m/andafeedof50mm/min/Thesurfa
4、ceroughnessRaofthespecimencanbeimprovedfromabout1/60mto0/35mbyusingtheoptimalparametersforsurfacegrinding/SurfaceroughnessRacanbefurtherimprovedfromabout0/343mto0/06mbyusingtheballburnishingprocesswiththeoptimalburnishingparameters/Applyingtheoptimalsurfacegrindingandburnishingparame-terssequentiall
5、ytoafine-milledfreeformsurfacemoldinsert/thesurfaceroughnessRaoffreeformsurfaceregiononthetestedpartcanbeimprovedfromabout2/15mto0/07m/KeywordsAutomatedsurfacefinishingBallburnishingprocessGrindingprocessSurfaceroughnessTaguchismethod1IntroductionPlasticsareimportantengineeringmaterialsduetotheirspe
6、cificcharacteristics/suchascorrosionresistance/resistancetochemi-cals/lowdensity/andeaseofmanufacture/andhaveincreasinglyF/-J/Shiou(a117)C/-C/A/ChenW/-T/LiDepartmentofMechanicalEngineering/NationalTaiwanUniversityofScienceandTechnology/No/43/Section4/KeelungRoad/106Taipei/TaiwanR/O/C/E-mail/shioumai
7、l/ntust/edu/twTel//+88-62-2737-6543Fax/+88-62-2737-6460replacedmetalliccomponentsinindustrialapplications/Injec-tionmoldingisoneoftheimportantformingprocessesforplas-ticproducts/Thesurfacefinishqualityoftheplasticinjectionmoldisanessentialrequirementduetoitsdirecteffectsontheappearanceoftheplasticpr
8、oduct/Finishingprocessessuchasgrinding/polishingandlappingarecommonlyusedtoimprovethesurfacefinish/Themountedgrindingtools(wheels)havebeenwidelyusedinconventionalmoldanddiefinishingindustries/Thegeometricmodelofmountedgrindingtoolsforautomatedsurfacefinish-ingprocesseswasintroducedin1/Afinishingproc
9、essmodelofsphericalgrindingtoolsforautomatedsurfacefinishingsys-temswasdevelopedin2/Grindingspeed/depthofcut/feedrate/andwheelpropertiessuchasabrasivematerialandabrasivegrainsize/arethedominantparametersforthesphericalgrind-ingprocess/asshowninFig/1/Theoptimalsphericalgrindingparametersfortheinjecti
10、onmoldsteelhavenotyetbeeninvesti-gatedbasedintheliterature/Inrecentyears/someresearchhasbeencarriedoutinde-terminingtheoptimalparametersoftheballburnishingpro-cess(Fig/2)/Forinstance/ithasbeenfoundthatplasticde-formationontheworkpiecesurfacecanbereducedbyusingatungstencarbideballoraroller/thusimprov
11、ingthesurfaceroughness/surfacehardness/andfatigueresistance36/Theburnishingprocessisaccomplishedbymachiningcenters3/4andlathes5/6/Themainburnishingparametershavingsignifi-canteffectsonthesurfaceroughnessareballorrollermaterial/burnishingforce/feedrate/burnishingspeed/lubrication/andnumberofburnishin
12、gpasses/amongothers3/Theoptimalsur-faceburnishingparametersfortheplasticinjectionmoldsteelPDS5wereacombinationofgreaselubricant/thetungstencar-bideball/aburnishingspeedof200mm/min/aburnishingforceof300N/andafeedof40m7/Thedepthofpenetrationoftheburnishedsurfaceusingtheoptimalballburnishingparametersw
13、asabout2/5microns/Theimprovementofthesurfacerough-nessthroughburnishingprocessgenerallyrangedbetween40%and90%37/Theaimofthisstudywastodevelopsphericalgrindingandballburnishingsurfacefinishprocessesofafreeformsurface62plasticinjectionmoldonamachiningcenter/Theflowchartofautomatedsurfacefinishusingsph
14、ericalgrindingandballbur-nishingprocessesisshowninFig/3/Webeganbydesigningandmanufacturingthesphericalgrindingtoolanditsalignmentde-viceforuseonamachiningcenter/TheoptimalsurfacesphericalgrindingparametersweredeterminedbyutilizingaTaguchisorthogonalarraymethod/Fourfactorsandthreecorrespondinglevelsw
15、erethenchosenfortheTaguchisL18matrixexperiment/Theoptimalmountedsphericalgrindingparametersforsurfacegrindingwerethenappliedtothesurfacefinishofafreeformsurfacecarrier/Toimprovethesurfaceroughness/thegroundsurfacewasfurtherburnished/usingtheoptimalballburnishingparameters/Fig/1/Schematicdiagramofthe
16、sphericalgrindingprocessFig/2/Schematicdiagramoftheball-burnishingprocessFig/3/Flowchartofautomatedsurfacefinishusingsphericalgrindingandballburnishingprocesses2DesignofthesphericalgrindingtoolanditsalignmentdeviceTocarryoutthepossiblesphericalgrindingprocessofafreeformsurface/thecenteroftheballgrin
17、dershouldcoincidewiththez-axisofthemachiningcenter/Themountedsphericalgrindingtoolanditsadjustmentdevicewasdesigned/asshowninFig/4/Theelectricgrinderwasmountedinatoolholderwithtwoad-justablepivotscrews/Thecenterofthegrinderballwaswellalignedwiththehelpoftheconicgrooveofthealignmentcom-ponents/Having
18、alignedthegrinderball/twoadjustablepivotscrewsweretightened；afterwhich/thealignmentcomponentscouldberemoved/Thedeviationbetweenthecentercoordi-natesoftheballgrinderandthatoftheshankwasabout5m/whichwasmeasuredbyaCNCcoordinatemeasuringmachine/Theforceinducedbythevibrationofthemachinebedisab-sorbedbyah
19、elicalspring/Themanufacturedsphericalgrind-ingtoolandball-burnishingtoolweremounted/asshowninFig/5/Thespindlewaslockedforboththesphericalgrindingprocessandtheballburnishingprocessbyaspindle-lockingmechanism/63Fig/4/Schematicillustrationofthesphericalgrindingtoolanditsadjust-mentdevice3Planningofthem
20、atrixexperiment3/1ConfigurationofTaguchisorthogonalarrayTheeffectsofseveralparameterscanbedeterminedefficientlybyconductingmatrixexperimentsusingTaguchisorthogonalarray8/Tomatchtheaforementionedsphericalgrindingpa-rameters/theabrasivematerialofthegrinderball(withthediam-eterof10mm)/thefeedrate/thede
21、pthofgrinding/andtherevolutionoftheelectricgrinderwereselectedasthefourexperi-mentalfactors(parameters)anddesignatedasfactorAtoD(seeTable1)inthisresearch/Threelevels(settings)foreachfactorwereconfiguredtocovertherangeofinterest/andwereidenti-Fig/5/aPhotoofthesphericalgrindingtoolbPhotooftheballburni
22、shingtoolTable1/TheexperimentalfactorsandtheirlevelsFactorLevel123A/AbrasivematerialSiCAl2O3/WAAl2O3/PAB/Feed(mm/min)50100200C/Depthofgrinding(m)205080D/Revolution(rpm)120001800024000fiedbythedigits1/2/and3/Threetypesofabrasivematerials/namelysiliconcarbide(SiC)/whitealuminumoxide(Al2O3/WA)/andpinka
23、luminumoxide(Al2O3/PA)/wereselectedandstudied/Threenumericalvaluesofeachfactorweredeterminedbasedonthepre-studyresults/TheL18orthogonalarraywasse-lectedtoconductthematrixexperimentforfour3-levelfactorsofthesphericalgrindingprocess/3/2DefinitionofthedataanalysisEngineeringdesignproblemscanbedividedin
24、tosmaller-the-bettertypes/nominal-the-besttypes/larger-the-bettertypes/signed-targettypes/amongothers8/Thesignal-to-noise(S/N)ratioisusedastheobjectivefunctionforoptimizingaproductorprocessdesign/Thesurfaceroughnessvalueofthegroundsur-faceviaanadequatecombinationofgrindingparametersshouldbesmallerth
25、anthatoftheoriginalsurface/Consequently/thesphericalgrindingprocessisanexampleofasmaller-the-bettertypeproblem/TheS/Nratio/isdefinedbythefollowingequation8/=10log10(meansquarequalitycharacteristic)=10log10bracketleftBigg1nnsummationdisplayi=1y2ibracketrightBigg/(1)where/yi/observationsofthequalitych
26、aracteristicunderdifferentnoiseconditionsn/numberofexperimentAftertheS/NratiofromtheexperimentaldataofeachL18orthogonalarrayiscalculated/themaineffectofeachfactorwasdeterminedbyusingananalysisofvariance(ANOVA)tech-niqueandanF-ratiotest8/Theoptimizationstrategyofthe64smaller-thebetterproblemistomaxim
27、ize/asdefinedbyEq/1/Levelsthatmaximizewillbeselectedforthefactorsthathaveasignificanteffecton/Theoptimalconditionsforsphericalgrindingcanthenbedetermined/4ExperimentalworkandresultsThematerialusedinthisstudywasPDS5toolsteel(equiva-lenttoAISIP20)9/whichiscommonlyusedforthemoldsoflargeplasticinjection
28、productsinthefieldofautomobilecom-ponentsanddomesticappliances/ThehardnessofthismaterialisaboutHRC33(HS46)9/Onespecificadvantageofthisma-terialisthataftermachining/themoldcanbedirectlyusedforfurtherfinishingprocesseswithoutheattreatmentduetoitsspecialpre-treatment/Thespecimensweredesignedandmanu-fac
29、turedsothattheycouldbemountedonadynamometertomeasurethereactionforce/ThePDS5specimenwasroughlyma-chinedandthenmountedonthedynamometertocarryoutthefinemillingonathree-axismachiningcentermadebyYang-IronCompany(typeMV-3A)/equippedwithaFUNUCCom-panyNC-controller(type0M)10/Thepre-machinedsurfaceroughness
30、wasmeasured/usingHommelwerkeT4000equip-ment/tobeabout1/6m/Figure6showstheexperimentalset-upofthesphericalgrindingprocess/AMP10touch-triggerprobemadebytheRenishawCompanywasalsointegratedwiththemachiningcentertoolmagazinetomeasureanddeterminethecoordinatedoriginofthespecimentobeground/TheNCcodesneeded
31、fortheball-burnishingpathweregeneratedbyPowerMILLCAMsoftware/ThesecodescanbetransmittedtotheCNCcontrollerofthemachiningcenterviaRS232serialinterface/Table2summarizesthemeasuredgroundsurfaceroughnessvalueRaandthecalculatedS/NratioofeachL18orthogonalar-rayusingEq/1/afterhavingexecutedthe18matrixexperi
32、ments/TheaverageS/Nratioforeachlevelofthefourfactorscanbeobtained/aslistedinTable3/bytakingthenumericalvaluespro-videdinTable2/TheaverageS/NratioforeachlevelofthefourfactorsisshowngraphicallyinFig/7/Fig/6/Experimentalset-uptodeterminetheop-timalsphericalgrindingparametersTable2/Groundsurfaceroughnes
33、sofPDS5specimenExp/InnerarrayMeasuredsurfaceResponseno/(controlfactors)roughnessvalue(Ra)ABCDy1y2y3S/NratioMean(m)(m)(m)(dB)y(m)111110/350/350/359/1190/350212220/370/360/388/6340/370313330/410/440/407/5970/417421230/630/650/643/8760/640522310/730/770/782/3800/760623120/450/420/397/5200/420731320/340
34、/310/329/8010/323832130/270/250/2811/4710/267933210/320/320/329/8970/3201011220/350/390/408/3900/3801112330/410/500/436/9680/4471213110/400/390/427/8830/4031321130/330/340/319/7120/3271422210/480/500/476/3120/4831523320/570/610/534/8680/5701631310/590/550/545/0300/5601732120/360/360/358/9540/3571833
35、230/570/530/535/2930/543Table3/AverageS/Nratiosbyfactorlevels(dB)FactorABCDLevel18/0997/6559/1106/770Level25/7787/4537/0678/028Level38/4087/1766/1077/486Effect2/6300/4793/0031/258Rank2413Mean7/428Thegoalinthesphericalgrindingprocessistominimizethesurfaceroughnessvalueofthegroundspecimenbydetermin-ingtheoptimallevelofeachfactor/Sincelogisamonotonedecreasingfunction/weshouldmaximizetheS/Nratio/Conse-quently/wecandeterminetheoptimallevelforeachfactorasbeingthelevelthathasthehighestvalueof/Therefore/based
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