Need of Lapping Machine for Valve Component: A Case Study – Mechanical projects

抽象的：

研磨过程的特点是其低速，低压和低材料去除率。该过程用于实现更精细的表面和更接近的拟合，较小的缺陷校正，并保持近距离的公差。在研磨过程中，表面形成和去除率的机制受到研磨磨料内的各个颗粒的运动类型的果断地影响。闸阀用于开始和停止流体流动。因此，阀门的楔形和座环是流体流量的连续压力，并且由于阀门的打开和关闭这些部件佩戴并且它们在修复过程中需要研磨。本文将分享阀门修复过程中研磨的需求，要求和应用。本文将探讨阀门行业研磨机的当前工作条件。它将详细阐述磨料局部，工作速度，表面粗糙度和其他相关参数的影响。他们在与研磨有关的阀门再现期间遇到的困难是什么样的。当前设置和该模型所需的更改与所提出的模型建议。

INTRODUCTION

Lapping is a micro finishing operation which is required to require getting a mirror like surface finish on the meting component. It provides a good strength to joint formed. Lapping has been used extensively in the manufacture of optical mirrors and lenses, ceramics, hard disk drive, semi-conductor wafers, valve seats, ball bearings, and, and many more parts. Several factors need to be considered during the process of lapping. This includes factors such as type of machine, condition of the lap plate surface, speed of the lap plate, type of abrasive, type of carrier fluid, slurry concentration, slurry flow rate, size and shape of abrasive, material of the lap plate, rigidity of the lap plate, applied force on the work piece, time of operation and duration between the two consecutive instances of application of fresh abrasive slurry.

需要研磨阀部件

阀门研磨是维护工作的重要组成部分，通常会中断生产工作。在工业中修复泄漏阀是一个艰苦的操作，涉及延长停机时间，生产损失和大量不需要的成本。给定的图示出了闸阀的不同部分。

COMPONENT THAT REQUIRE LAPPING

阀门的楔子：

这是阀门的楔形阀，其在连续的流体流动压力下。楔形尺寸根据例如阀门的尺寸而变化，例如2“，4”，6“等阀门。要关闭阀门，这些楔形与座环是啮合。在60-70开口阀门开口后，这些楔子需要研磨。为了获得泄漏证据，这些部分需要研磨。

座圈：

楔形闸板或阀瓣与阀座环网格的阀门。It is actually a ring made up of stainless steel , bronze etc. material. The shape of seat ring goes on changing with continuous use. It becomes tapered and get leaked so it requires lapping. Size of seat ring also varies as per the size of valve. Small size seat rings are either press fitted or they may be welded to sustain fluid pressure.

DEVELOPMENT OF LAPPING MACHINE

A visit to an industry it is being observed that they were performing lapping operation on a set up which was developed by them. They fixed the lapping tool to the conventional lapping machine which is fixed. They fixed the valve on a vice and perform lapping on the valves. Observing the operation we are trying to propose on model which will be portable, can be handled y one person and it will reduce the set up time also.

PROPOSED MODEL OF LAPPING MACHINE

使用高扭矩钻孔机，其将产生约240rpm的轴速度。通过该轴RPM转移到减速齿轮箱，将其将其降低至80-100 rpm。这种速度最适合执行低速研磨操作。该齿轮箱安装在保持板上，该齿轮有孔。该板将帮助我们在框架上握住框架，以便研磨楔形或保持在阀体上的设置。轴通过该齿轮箱与由铸铁组成的研磨板连接。中心提供指导，以保持圈稳定。座环和阀体之间的距离将根据阀门的尺寸而变化。因此，轴长度将根据阀门的尺寸。

ABRASIVE MATERIAL USED FOR LAPPING

The most commonly used abrasive materials for lapping of valves seats are alumina and silicon carbide. It is the objective of this research to obtain sufficient data by lapping. Three types of abrasives: (1) garnet, (2) alun-dum (aluminum oxide), and (3) crystolon (silicon carbide) (4) CARBURANDM (silicon carbide) were used to lap the work pieces. Generally, the high peaks are abraded by coarse grains of average diameter about 80 mm (F80: coarse lapping), the average height s peak s by grain size between 40 and 20 mm (F40 and F20: average lapping ) and the low height s peaks by fine grain size of 7 mm (F7: fine lapping ) are available for lapping. We will perform coarse lapping and fine lapping on valve component.

CONCLUSION

上述研究工作和所提出的模型可以在阀门部件的研磨中提供益处。模型将提供可移植性，并减少设置时间以便在某种程度上进行研磨。本文显示了阀门行业中研磨操作的重要性。它显示用于阀门研磨的磨料的尺寸和类型。与可用机器相比，用于研磨的可用机器，该建议的模型将是更便宜的模型。它将被证明是一个经济的模式。劳动力的数量要求操作本机只是一个且技能劳动力较少的劳动力可以操作该模型。

参考和下载：

http://www.ijmer.com/papers/vol2_issue6/ej2646094612.pdf.