电火花加工钛合金的实验及脉冲电源的研究
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摘要
钛合金广泛应用于航空、航天产业为首的各种领域中,随着它的深入应用,利用传统的加工方法很难达到加工要求。而电火花加工适合于任何难切削材料的加工,并且可以加工特殊及复杂形状的表面和零件。脉冲电源是电火花加工机床的主要组成部分,并且是影响电火花加工工艺指标关键的设备之一。
本文首先在总结前人研究成果的基础上,对电火花加工钛合金的可行性进行了分析。其次,进行了电火花加工钛合金的对比实验,结果表明窄脉宽加工钛合金时,用等频方波、正极性、低电压,电极相对损耗比较小。再次,进行了正交实验,结果表明脉宽和峰值电流对加工效率及电极相对损耗的影响较显著,并得到了各个电参数与加工效率和电极相对损耗之间的关系曲线。实验结果还表明:常规的脉冲电源加工钛合金时,效率不高,加工不稳定。本文认为主要是由于瞬时放电能量不足以使钛合金完全气化,且抛出作用不强,容易形成短路。最后,针对电火花加工钛合金的特点,本文研制了以单片机为核心的脉冲电源,并进行了加工工艺实验和对比实验,实验结果表明,利用RC回路中电容的储能作用提供较大的瞬时放电能量,增强了材料的抛出作用,从而提高了加工的稳定性和加工效率。
The titanium alloy is widely used in various fields especially in the aviation and spaceflight industry. Along with the titanium alloy extensively used, it’s difficult for traditional machining method to machine titanium alloy. However, electrical discharge machining (EDM) can be used to machine various hard processing materials, and it can machine the special and complex shape surface and parts. The pulse power supply is the most important part of electric discharge machining machine tool. It is one of the key equipments that influence various parameters of EDM.
Firstly, on the basis of review of other researchers’work, this paper analyzes the feasibility that EDM machining titanium alloy. Secondly, this paper does comparing experiment of EDM processing titanium alloy. The results indicate that electrode dissipation is low with equifrequence square wave, negative polarity and low supply voltage to machining titanium alloy when pulse width is narrow. Thirdly, this paper has done the orthogonal experiment and gets relational curves between electric parameters and machining efficiency, electrode dissipation. Its result shows that pulse width and peak current have a great influence on the machining efficiency and electrode dissipation. It also shows that when the routine pulse power supply machines the titanium alloy, the efficiency is low and procedure is unstable because that inadequate instantaneous discharge energy can not gasify the titanium alloy and casting effect is week. All these reasons easily generate short circuit. At last, considering the trait of processing titanium alloy with EDM, this paper designs pulse power supply with the single chip process as the core, and carries out the experiment on both technology and contrast. The experiment results indicate that greater instantaneous discharge energy will be produced by using the capacitance of RC circuit with the stored energy function, and the function of material emitting will be improved, so efficiency and stability of processing will be enhanced.
本文首先在总结前人研究成果的基础上,对电火花加工钛合金的可行性进行了分析。其次,进行了电火花加工钛合金的对比实验,结果表明窄脉宽加工钛合金时,用等频方波、正极性、低电压,电极相对损耗比较小。再次,进行了正交实验,结果表明脉宽和峰值电流对加工效率及电极相对损耗的影响较显著,并得到了各个电参数与加工效率和电极相对损耗之间的关系曲线。实验结果还表明:常规的脉冲电源加工钛合金时,效率不高,加工不稳定。本文认为主要是由于瞬时放电能量不足以使钛合金完全气化,且抛出作用不强,容易形成短路。最后,针对电火花加工钛合金的特点,本文研制了以单片机为核心的脉冲电源,并进行了加工工艺实验和对比实验,实验结果表明,利用RC回路中电容的储能作用提供较大的瞬时放电能量,增强了材料的抛出作用,从而提高了加工的稳定性和加工效率。
The titanium alloy is widely used in various fields especially in the aviation and spaceflight industry. Along with the titanium alloy extensively used, it’s difficult for traditional machining method to machine titanium alloy. However, electrical discharge machining (EDM) can be used to machine various hard processing materials, and it can machine the special and complex shape surface and parts. The pulse power supply is the most important part of electric discharge machining machine tool. It is one of the key equipments that influence various parameters of EDM.
Firstly, on the basis of review of other researchers’work, this paper analyzes the feasibility that EDM machining titanium alloy. Secondly, this paper does comparing experiment of EDM processing titanium alloy. The results indicate that electrode dissipation is low with equifrequence square wave, negative polarity and low supply voltage to machining titanium alloy when pulse width is narrow. Thirdly, this paper has done the orthogonal experiment and gets relational curves between electric parameters and machining efficiency, electrode dissipation. Its result shows that pulse width and peak current have a great influence on the machining efficiency and electrode dissipation. It also shows that when the routine pulse power supply machines the titanium alloy, the efficiency is low and procedure is unstable because that inadequate instantaneous discharge energy can not gasify the titanium alloy and casting effect is week. All these reasons easily generate short circuit. At last, considering the trait of processing titanium alloy with EDM, this paper designs pulse power supply with the single chip process as the core, and carries out the experiment on both technology and contrast. The experiment results indicate that greater instantaneous discharge energy will be produced by using the capacitance of RC circuit with the stored energy function, and the function of material emitting will be improved, so efficiency and stability of processing will be enhanced.
引文
1李卫民,曹秀洪.影响钛合金机械加工因素的分析与研究.泰州职业技术学院学报. 2003, 3(1): 18~20
2刘晋春,赵家齐,赵万生.特种加工.机械工业出版社,2005: 8~9
3伍俊,李明辉.浅谈高速走丝电火花线切割加工技术的发展趋势.电加工与模具. 2000, (2): 2~4
4 CIMT’99特种加工机床评述组.第六届中国国际机床展览会特种加工机床展品水平分析.电加工与模具. 2000, (1): 1~10
5张学仁.数控电火花线切割加工技术.哈尔滨:哈尔滨工业大学出版社,2000, 1~5
6 Zhao wansheng, Zhu Di, Wang Zhenglong, Guo Dongming. Research and Development of Nontraditional Machining in China. International Journal of Electrical Machining. 2000, (5):1~6
7 G.. Walder. New Technologies and EDM. 12th International Symposium for Electromachining(ISEM-12). VDI-Gesellschaft Produktionstechnik(ADB), Aac- hen Germany.1998, (5): 331~340
8 CIMT 2005特种加工机床评述专家组.第九届中国国际机床展览会特种加工机床展品评述.WMEW, 2005, (5): 42~49
9狄士春,王弢,于滨,赵万生.电火花加工脉冲电源研究现状与发展趋势.机械工程师. 2002, 10: 6~9
10智能化的AGIE IPG电源.模具制造. 2001, (4): 56
11陈德忠. CIMT2001电加工机床技术评述. WMEW. 2001, (5): 28~31
12沈洪. CIMT2001电火花机床评述.制造技术与机床. 2001, (6): 12~17
13陈石宁.北京阿奇公司推出SC系列电火花成型机.制造技术与机床. 2000, (6): 55
14 Takuji Magara. Power Source for Electric Discharge Machining. United States Patent Number: 5149931
15 CIMT 2003特种加工机床评述专家组. CIMT 2003特种加工机床展品评述. WMEM. 2003, (5): 35~40
16 CIMT 2003特种加工机床评述专家组.第八届中国国际机床展览会特种加工机床展品评述.电加工与模具. 2003, (3): 1~11
17宋博岩. PWM控制节能式电火花加工脉冲电源的研究.哈尔滨工业大学博士学位论文. 2001: 31~32
18北京机电研究院. BJD45NC精密数控电火花成型机床.电加工. 1995, (2): 43
19韦东波,狄士春,迟关心,赵万生.新型节能电火花加工脉冲电源的脉冲发生器.功能部件. 2006, (11): 94~97
20韦东波,狄士春,迟关心,赵万生.循环叠加斩波式电火花加工脉冲电源节能效果分析.电加工与模具. 2006, (3): 45~48
21狄士春,韦东波,姜吉涛,迟关心.新型节能电火花加工脉冲电源的研究.航空精密制造技术. 2006, 42(1): 33~35
22霍孟友,艾兴,张建华.电火花精微加工脉冲电源设计.新技术新工艺. 1999, (6): 7~8
23曹凤国,桂小波.大面积PCD复合片电火花加工高效节能脉冲电源的研究.金刚石与磨料磨具工程:2004, (2): 17~24
24郭金全.难加工材料电火花加工脉冲电源的研究.哈尔滨工业大学硕士学位论文. 2006: 6~7
25高效电加工技术在航空航天制造业广泛应用.http://baike.machine365. com/arts/070117/24/169126.html
26沉思.钛合金的开发和应用.金属. 2000, 70(1): 61
27赵树萍,吕双坤.钛合金在航空航天领域中的应用.钛工业进展. 2002, (6): 18~21
28 DonachieM J. Titanium-A Technical Guide, ASM International. New York: The Materials Information Society, 2000
29 Anon. Titanium alloys for aerospace. Advanced Materials & Processes. 1999, 155(3): 39
30 Lineberger, Lane. Titanium aerospace alloys. Advanced Materials & Processes. 1998, 153(5): 45
31 The F-22 Story: Building Affordability. Flight lnternational Supplement. 1997, (4): 9
32李文平.钛合金的应用现状及发展前景.轻金属. 2002, (5): 53~55
33 BRANEMARK P, BREINE U, LINDSTROM J, et al. Intraosseous anchorage of dental prostheses: I experimental studies. Scand J Plast Reconstr Surg. 1969, 3: 81~82
34 BRANEMARK P, HANSSON B, ADELL R, et al. Osseointegrated implants in the treatment of edentulous jaw: experience form a 10~year period. Scand J Reconstr Surg Suppl. 1977, 16: 1~4
35 LONG M, RACK H J. Titanium alloys in total joint replacement——a material science perspective. Biomaterials. 2003, 19: 1621~1639
36 WANG K. The use of titanium for medical application in the USA. Mater Sci Eng. 1996, A213: 134~137
37 NINOMI M, KURODA D, FUKUNAGA K, et al. Corrosion wear fracture of newβType biomedical titanium alloys. Mater Sci Eng. 2003, A263: 193~199
38 KURODAD, NIINOMIM, MORINAGAM, et al. Design and mechanical properties of NewβType titanium alloys for implant materials. Mater Sci Eng. 2004, A243: 244~249
39 VAN NOORTR. Titanium: the implant of today. J Mater Sei. 1987, 22: 3801~ 3811
40 WANGK. The use of titanium for medical application in the USA. Mater Sci Eng. 1996, A213: 134-137
41蒋成禹,徐济进,严铿,赵勇.俄罗斯海军用钛情况及我们的思考.钛工业进展. 2003, 12(6): 32~36
42 Opet S L, Peter D F. Beta Titanium in the United States Surface Navy Improved Water Brake. In: Froes F H, Caplan I eds.Titanium’92: Science and Technology. Pensylvania: The Minerals, Metals & materials Society. 1993: 2711~2728
43 Russo P A, Wood J R, Bhagat R B et al, High Structural Applications for Large Diammeter Foging of Beta-CTM(Ti-3Al-8V-6Cr-4Mo-4Zr). InEylon D, Boyer R R, Koss D A eds. Beta Titanium alloys in the 1990’s. Pennsylvania: The Minerals, Metals & Material Society. 1993: 361~374
44宁兴龙.俄罗斯舰船用钛.钛工业进展. 2003, 20(6): 28~31
45 Shira, Chet, Froes F H. Titanium golf clubs. TMS Annual Meeting, Sponsored by: TMS Minerals. Metals & Materials Soc(TMS). 1998, Feb, 331:16~19
46 Vandermark, Robert. Opportunities for the titanium industry in bicycles and wheelchairs. JOM. 2002, 49 (6): 24
47 Yamamoto, Yoshitaka. Development of titanium products for consumer, sports and leisure goods. Research and Development Kobe Steel Engineering Reports. 2004, 68
48赵伟,任延华,任中根,方宗德.钛合金TC4的电火花放电研究.机械科学与技术. 2003, 11(22): 167~168
49王振龙,夏良俊,赵万生.半导体硅材料的电火花加工技术研究.电加工与模具. 2004, (1): 13~16
50王克锡编译.钛合金的电火花加工.机械工人. 2004, (1): 24
51王振龙,迟关心,狄士春,赵万生.钛合金深小孔的微细超声电火花加工技术.兵工学报. 2000, 11(21): 346~349
52刘振学,黄仁和,田爱民编著.实验设计与数据处理.化学工业出版社,2005: 62~75
53蒋超,陈海民.电力电子器件发展概况及应用现状.世界电子元器件. 2004, (4): 74~76
54刘永红,肖志明,杜建华,苗春彦,洪能国.电火花加工脉冲电源功率器件的研究进展.制造业自动化. 2005, 27(3): 58~61
55 Lazlo Balogh. Design And Application Guide for High Speed MOSFET Gate Drive Circuits. Texts Instruments, Application Note INT978
56张占松,蔡宣三.开关电源的原理和应用.电子工业出版社,1998: 114~ 124
57 R. Chekhawala, J. Catt, B. Pelly. Gate Drive Consideration for IGBT Modules. LAS-IEEE Conf, October, 1992: 51~57
58李广第,朱月秀,王秀山编著.单片机基础.北京航空航天大学出版社, 2001: 147~156
2刘晋春,赵家齐,赵万生.特种加工.机械工业出版社,2005: 8~9
3伍俊,李明辉.浅谈高速走丝电火花线切割加工技术的发展趋势.电加工与模具. 2000, (2): 2~4
4 CIMT’99特种加工机床评述组.第六届中国国际机床展览会特种加工机床展品水平分析.电加工与模具. 2000, (1): 1~10
5张学仁.数控电火花线切割加工技术.哈尔滨:哈尔滨工业大学出版社,2000, 1~5
6 Zhao wansheng, Zhu Di, Wang Zhenglong, Guo Dongming. Research and Development of Nontraditional Machining in China. International Journal of Electrical Machining. 2000, (5):1~6
7 G.. Walder. New Technologies and EDM. 12th International Symposium for Electromachining(ISEM-12). VDI-Gesellschaft Produktionstechnik(ADB), Aac- hen Germany.1998, (5): 331~340
8 CIMT 2005特种加工机床评述专家组.第九届中国国际机床展览会特种加工机床展品评述.WMEW, 2005, (5): 42~49
9狄士春,王弢,于滨,赵万生.电火花加工脉冲电源研究现状与发展趋势.机械工程师. 2002, 10: 6~9
10智能化的AGIE IPG电源.模具制造. 2001, (4): 56
11陈德忠. CIMT2001电加工机床技术评述. WMEW. 2001, (5): 28~31
12沈洪. CIMT2001电火花机床评述.制造技术与机床. 2001, (6): 12~17
13陈石宁.北京阿奇公司推出SC系列电火花成型机.制造技术与机床. 2000, (6): 55
14 Takuji Magara. Power Source for Electric Discharge Machining. United States Patent Number: 5149931
15 CIMT 2003特种加工机床评述专家组. CIMT 2003特种加工机床展品评述. WMEM. 2003, (5): 35~40
16 CIMT 2003特种加工机床评述专家组.第八届中国国际机床展览会特种加工机床展品评述.电加工与模具. 2003, (3): 1~11
17宋博岩. PWM控制节能式电火花加工脉冲电源的研究.哈尔滨工业大学博士学位论文. 2001: 31~32
18北京机电研究院. BJD45NC精密数控电火花成型机床.电加工. 1995, (2): 43
19韦东波,狄士春,迟关心,赵万生.新型节能电火花加工脉冲电源的脉冲发生器.功能部件. 2006, (11): 94~97
20韦东波,狄士春,迟关心,赵万生.循环叠加斩波式电火花加工脉冲电源节能效果分析.电加工与模具. 2006, (3): 45~48
21狄士春,韦东波,姜吉涛,迟关心.新型节能电火花加工脉冲电源的研究.航空精密制造技术. 2006, 42(1): 33~35
22霍孟友,艾兴,张建华.电火花精微加工脉冲电源设计.新技术新工艺. 1999, (6): 7~8
23曹凤国,桂小波.大面积PCD复合片电火花加工高效节能脉冲电源的研究.金刚石与磨料磨具工程:2004, (2): 17~24
24郭金全.难加工材料电火花加工脉冲电源的研究.哈尔滨工业大学硕士学位论文. 2006: 6~7
25高效电加工技术在航空航天制造业广泛应用.http://baike.machine365. com/arts/070117/24/169126.html
26沉思.钛合金的开发和应用.金属. 2000, 70(1): 61
27赵树萍,吕双坤.钛合金在航空航天领域中的应用.钛工业进展. 2002, (6): 18~21
28 DonachieM J. Titanium-A Technical Guide, ASM International. New York: The Materials Information Society, 2000
29 Anon. Titanium alloys for aerospace. Advanced Materials & Processes. 1999, 155(3): 39
30 Lineberger, Lane. Titanium aerospace alloys. Advanced Materials & Processes. 1998, 153(5): 45
31 The F-22 Story: Building Affordability. Flight lnternational Supplement. 1997, (4): 9
32李文平.钛合金的应用现状及发展前景.轻金属. 2002, (5): 53~55
33 BRANEMARK P, BREINE U, LINDSTROM J, et al. Intraosseous anchorage of dental prostheses: I experimental studies. Scand J Plast Reconstr Surg. 1969, 3: 81~82
34 BRANEMARK P, HANSSON B, ADELL R, et al. Osseointegrated implants in the treatment of edentulous jaw: experience form a 10~year period. Scand J Reconstr Surg Suppl. 1977, 16: 1~4
35 LONG M, RACK H J. Titanium alloys in total joint replacement——a material science perspective. Biomaterials. 2003, 19: 1621~1639
36 WANG K. The use of titanium for medical application in the USA. Mater Sci Eng. 1996, A213: 134~137
37 NINOMI M, KURODA D, FUKUNAGA K, et al. Corrosion wear fracture of newβType biomedical titanium alloys. Mater Sci Eng. 2003, A263: 193~199
38 KURODAD, NIINOMIM, MORINAGAM, et al. Design and mechanical properties of NewβType titanium alloys for implant materials. Mater Sci Eng. 2004, A243: 244~249
39 VAN NOORTR. Titanium: the implant of today. J Mater Sei. 1987, 22: 3801~ 3811
40 WANGK. The use of titanium for medical application in the USA. Mater Sci Eng. 1996, A213: 134-137
41蒋成禹,徐济进,严铿,赵勇.俄罗斯海军用钛情况及我们的思考.钛工业进展. 2003, 12(6): 32~36
42 Opet S L, Peter D F. Beta Titanium in the United States Surface Navy Improved Water Brake. In: Froes F H, Caplan I eds.Titanium’92: Science and Technology. Pensylvania: The Minerals, Metals & materials Society. 1993: 2711~2728
43 Russo P A, Wood J R, Bhagat R B et al, High Structural Applications for Large Diammeter Foging of Beta-CTM(Ti-3Al-8V-6Cr-4Mo-4Zr). InEylon D, Boyer R R, Koss D A eds. Beta Titanium alloys in the 1990’s. Pennsylvania: The Minerals, Metals & Material Society. 1993: 361~374
44宁兴龙.俄罗斯舰船用钛.钛工业进展. 2003, 20(6): 28~31
45 Shira, Chet, Froes F H. Titanium golf clubs. TMS Annual Meeting, Sponsored by: TMS Minerals. Metals & Materials Soc(TMS). 1998, Feb, 331:16~19
46 Vandermark, Robert. Opportunities for the titanium industry in bicycles and wheelchairs. JOM. 2002, 49 (6): 24
47 Yamamoto, Yoshitaka. Development of titanium products for consumer, sports and leisure goods. Research and Development Kobe Steel Engineering Reports. 2004, 68
48赵伟,任延华,任中根,方宗德.钛合金TC4的电火花放电研究.机械科学与技术. 2003, 11(22): 167~168
49王振龙,夏良俊,赵万生.半导体硅材料的电火花加工技术研究.电加工与模具. 2004, (1): 13~16
50王克锡编译.钛合金的电火花加工.机械工人. 2004, (1): 24
51王振龙,迟关心,狄士春,赵万生.钛合金深小孔的微细超声电火花加工技术.兵工学报. 2000, 11(21): 346~349
52刘振学,黄仁和,田爱民编著.实验设计与数据处理.化学工业出版社,2005: 62~75
53蒋超,陈海民.电力电子器件发展概况及应用现状.世界电子元器件. 2004, (4): 74~76
54刘永红,肖志明,杜建华,苗春彦,洪能国.电火花加工脉冲电源功率器件的研究进展.制造业自动化. 2005, 27(3): 58~61
55 Lazlo Balogh. Design And Application Guide for High Speed MOSFET Gate Drive Circuits. Texts Instruments, Application Note INT978
56张占松,蔡宣三.开关电源的原理和应用.电子工业出版社,1998: 114~ 124
57 R. Chekhawala, J. Catt, B. Pelly. Gate Drive Consideration for IGBT Modules. LAS-IEEE Conf, October, 1992: 51~57
58李广第,朱月秀,王秀山编著.单片机基础.北京航空航天大学出版社, 2001: 147~156