混粉电火花加工机理及关键技术研究
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摘要
混粉电火花加工是通过在常规的煤油基工作液中添加硅、铝等微细粉末来改善放电状态,从而提高表面质量、精加工效率的一种新型加工工艺,能够有效地缓解放电面积和表面质量之间的矛盾、并可显著提高被加工件的表面性能。因此混粉电火花加工技术在模具型腔的大面积光整加工中表现出优越的潜在能力,越来越受到航空航天、汽车、精密机械等行业的重视。
电火花加工技术的放电机理非常复杂,涉及到工作液、工件和电极材料、电源特性、工艺参数等许多因素,而混粉电火花加工中悬浮粉末材料、粒度、浓度改变工作液的介电性能,从而影响电火花放电机制。因此,结合粉末特性以及粉末之间的相互影响来建立粉末—工作液两相混合作用基础,研究混粉电火花加工放电击穿理论,分析工件表面性能和电极损耗机理,必将推动混粉电火花加工工艺的改进和经济成本的降低。
本论文针对当今混粉电火花加工技术研究的热点问题,主要开展了如下四个方面的研究工作:
1.建立混粉工作液液固两相体复合作用理论基础:在讨论粉末性质、尺寸、浓度以及其相互作用对放电过程的影响的基础上,提出新型粉末结构并进行系统分析;研究粉末团聚机理并提出防止粉末团聚的措施;初步建立混粉电火花加工的液固两相体混合理论,为自主开发更符合混粉电火花加工要求的新型粉末提供理论支持。
2.研究混粉电火花加工技术的放电机理:以等离子体理论和电介质理论为基础,分析了放电通道的产生、发展到击穿等一系列阶段;用电树枝概念表征放电通道的生长的过程,论述混粉电火花加工中放电通道的形成机制、并分析了放电工艺参数以及添加粉末对放电通道的影响规律;得出了混粉电火花加工加工稳定性和加工质量提高的重要原因。
3.分析实验、总结工艺规范:通过实验观察放电加工过程中工件和电极表面残留的黑斑的大小和位置变化情况,分析微观形貌、粉末浓度分布等对放电点变化的影响,并以威布尔分布模型为基础推导出混粉电火花连续放电加工中放电点位置变化的规律;在优化实验的基础上系统分析了电规准对表面性能、加工损耗的影响;深入研究电极损耗的机理;总结了混粉电火花加工工艺规范。
4.电火花加工的仿真技术:借助有限元方法分析粉末对放电间隙中的电场、等离子体通道的作用,影响电极损耗的因素;同时运用神经网络实现混粉电火花加工工艺的仿真。
上述研究工作既有利于对电火花放电现象的认识和了解,为掌握混合两相体的击穿特性和击穿机理、精密电火花加工工艺提供理论依据,同时也为工业应用提供技术支持。
Powder mixed EDM (PMEDM) can assuage the contradiction between discharge area and surface roughness; effectively improves the discharge state in machining gap and surface properties of workpiece, and has potential ability in die&mould large-area finishing technology. EDM is getting more and more attentions in the fields of the aviation and the aerospace, precision machinery, automobile and electric industry.
Discharging process of EDM is more complex, there are many factors to be considered, such as performance properties of fluid, material of workpiece and electrode, character of power supply, process parameters and so on. Suspended powder changes dielectric characteristics of fluid in PMEDM, consequently discharge mechanism is affected. Based on powder characteristic, interaction among powders, powder-liquid two-phase mixture, effects of powders upon tree growth and discharge breakdown mechanism, mechanism and compensation of electrode loss are studied in this dissertation.
According to the hot research of PMEDM, the main contents of the dissertation are as following:
1. Establishing theoretical system of powder mixed dielectric fluid: Eliminetion methods and mechanism of agglomeration of powders are studied; Considering the electric field aberration in the inter-electrode gap caused by the particles, the polarization of electric field is calculated, concentration, characteristics, size, interaction of powders and their influence on electric field are analyzed, theoretical system of powder mixed dielectric fluid is preliminary established. The results provide theoretical basis for the determination of powder size, concentration, characteristics.
2. Theoretical study of discharge in PMEDM: Effects of additive powders on the machining mechanism of PMEDM are discussed based on theory of plasma and dielectric. By analyzing the inception, growth of electrical tree and the ignition of discharges in liquid filled gap, the whole discharging process are proposed. Influence of particles on electrical tree is analyzed. It is explored that the reason of modification of ignition behaves by fine particle powders of metal or semiconductor. Particles attract electrical trees, so the growth of electrical trees is more quick and dispersive. Therefore, the discharge channels is apt to establish and increases much more in PMEDM than in conventional EDM, which accounts for the improvement in working stability of PMEDM.
3. Experimental study: Law of location change of discharging is studied experimentally in PMEDM. Weibull distribution is developed from the basic theoretical model, effects of powder concentration, microcosmic profile of particle on discharge change is researched, and dependency of successive discharging spot is analyzed. Results show law of discharging location is determined by powder concentration, microcosmic profile and tool-lifting frequency; the positions correlate to each other to some extent. Orthogonal experimental method and ANOVA are used to analyze machining parameters on electrode loss and surface roughness; technology specification is summarized in the dissertation.
4. Simulation study: Discharging occurs in micro (time and space) scale, microenergy Environment. A 3D electric fields model described by finite element methods of the particles suspended in working fluid in the electric field is built; law of electric field change with electrode loss is simulated. ANNs with back propagation algorithm coupled with an orthogonal design was applied to the modeling of the PMEDM system. The results those methods are helpful to guide application and the work also accelerates research on PMEDM.
The research will be beneficial to understanding discharging as well as to providing theoretical basis for mastering breakdown mechanism and processing technology of EDM; meanwhile, it will be offer technical support for the industrial application.
电火花加工技术的放电机理非常复杂,涉及到工作液、工件和电极材料、电源特性、工艺参数等许多因素,而混粉电火花加工中悬浮粉末材料、粒度、浓度改变工作液的介电性能,从而影响电火花放电机制。因此,结合粉末特性以及粉末之间的相互影响来建立粉末—工作液两相混合作用基础,研究混粉电火花加工放电击穿理论,分析工件表面性能和电极损耗机理,必将推动混粉电火花加工工艺的改进和经济成本的降低。
本论文针对当今混粉电火花加工技术研究的热点问题,主要开展了如下四个方面的研究工作:
1.建立混粉工作液液固两相体复合作用理论基础:在讨论粉末性质、尺寸、浓度以及其相互作用对放电过程的影响的基础上,提出新型粉末结构并进行系统分析;研究粉末团聚机理并提出防止粉末团聚的措施;初步建立混粉电火花加工的液固两相体混合理论,为自主开发更符合混粉电火花加工要求的新型粉末提供理论支持。
2.研究混粉电火花加工技术的放电机理:以等离子体理论和电介质理论为基础,分析了放电通道的产生、发展到击穿等一系列阶段;用电树枝概念表征放电通道的生长的过程,论述混粉电火花加工中放电通道的形成机制、并分析了放电工艺参数以及添加粉末对放电通道的影响规律;得出了混粉电火花加工加工稳定性和加工质量提高的重要原因。
3.分析实验、总结工艺规范:通过实验观察放电加工过程中工件和电极表面残留的黑斑的大小和位置变化情况,分析微观形貌、粉末浓度分布等对放电点变化的影响,并以威布尔分布模型为基础推导出混粉电火花连续放电加工中放电点位置变化的规律;在优化实验的基础上系统分析了电规准对表面性能、加工损耗的影响;深入研究电极损耗的机理;总结了混粉电火花加工工艺规范。
4.电火花加工的仿真技术:借助有限元方法分析粉末对放电间隙中的电场、等离子体通道的作用,影响电极损耗的因素;同时运用神经网络实现混粉电火花加工工艺的仿真。
上述研究工作既有利于对电火花放电现象的认识和了解,为掌握混合两相体的击穿特性和击穿机理、精密电火花加工工艺提供理论依据,同时也为工业应用提供技术支持。
Powder mixed EDM (PMEDM) can assuage the contradiction between discharge area and surface roughness; effectively improves the discharge state in machining gap and surface properties of workpiece, and has potential ability in die&mould large-area finishing technology. EDM is getting more and more attentions in the fields of the aviation and the aerospace, precision machinery, automobile and electric industry.
Discharging process of EDM is more complex, there are many factors to be considered, such as performance properties of fluid, material of workpiece and electrode, character of power supply, process parameters and so on. Suspended powder changes dielectric characteristics of fluid in PMEDM, consequently discharge mechanism is affected. Based on powder characteristic, interaction among powders, powder-liquid two-phase mixture, effects of powders upon tree growth and discharge breakdown mechanism, mechanism and compensation of electrode loss are studied in this dissertation.
According to the hot research of PMEDM, the main contents of the dissertation are as following:
1. Establishing theoretical system of powder mixed dielectric fluid: Eliminetion methods and mechanism of agglomeration of powders are studied; Considering the electric field aberration in the inter-electrode gap caused by the particles, the polarization of electric field is calculated, concentration, characteristics, size, interaction of powders and their influence on electric field are analyzed, theoretical system of powder mixed dielectric fluid is preliminary established. The results provide theoretical basis for the determination of powder size, concentration, characteristics.
2. Theoretical study of discharge in PMEDM: Effects of additive powders on the machining mechanism of PMEDM are discussed based on theory of plasma and dielectric. By analyzing the inception, growth of electrical tree and the ignition of discharges in liquid filled gap, the whole discharging process are proposed. Influence of particles on electrical tree is analyzed. It is explored that the reason of modification of ignition behaves by fine particle powders of metal or semiconductor. Particles attract electrical trees, so the growth of electrical trees is more quick and dispersive. Therefore, the discharge channels is apt to establish and increases much more in PMEDM than in conventional EDM, which accounts for the improvement in working stability of PMEDM.
3. Experimental study: Law of location change of discharging is studied experimentally in PMEDM. Weibull distribution is developed from the basic theoretical model, effects of powder concentration, microcosmic profile of particle on discharge change is researched, and dependency of successive discharging spot is analyzed. Results show law of discharging location is determined by powder concentration, microcosmic profile and tool-lifting frequency; the positions correlate to each other to some extent. Orthogonal experimental method and ANOVA are used to analyze machining parameters on electrode loss and surface roughness; technology specification is summarized in the dissertation.
4. Simulation study: Discharging occurs in micro (time and space) scale, microenergy Environment. A 3D electric fields model described by finite element methods of the particles suspended in working fluid in the electric field is built; law of electric field change with electrode loss is simulated. ANNs with back propagation algorithm coupled with an orthogonal design was applied to the modeling of the PMEDM system. The results those methods are helpful to guide application and the work also accelerates research on PMEDM.
The research will be beneficial to understanding discharging as well as to providing theoretical basis for mastering breakdown mechanism and processing technology of EDM; meanwhile, it will be offer technical support for the industrial application.
引文
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