磁场与电火花复合加工的机理研究与实验分析
|
摘要
随着科学技术的发展，在航空、航天、机械、电子、汽车、医疗、光学、模具、化纤、材料、轻工等行业和部门要求进行各种复杂表面的加工，各种超精、光整或具有特殊要求的零件的加工越来越多。针对以上复杂零件加工的特殊要求，仅仅依靠传统的电火花加工方法很难实现。传统的电火花加工尽管可以加工各种难切削材料和各种复杂表面的工件，但其加工速度慢、小孔加工中排屑困难、加工不稳定、电极易损耗等缺点也直接影响其实际应用。目前，国内外学者和工程技术人员对磁力、电火花、超声波等各种能量单独作用于零件的成型、光整的机理和工艺规律都有研究，成型的加工机床已在应用，机械电火花复合加工，电火花超声波复合加工，磁场电化学复合加工等两种能量的复合也有研究，这些加工方法都有不同的特点和优势，也各有其局限性。但是，磁、电两种能量的复合，磁场和电火花复合加工还未见报道。而磁场电火花复合加工可实现优势互补，显著地提高加工效率，改善零件表面质量，并且对电火花单独加工的不足有明显的改善。
本论文对磁场电火花复合加工这种新的复合加工的机理、工艺和复合加工的磁路设计进行了研究和探索，在此基础上，建立了磁场电火花复合加工的参数模型，同时通过大量的随着电流变化磁场电火花复合前后加工速度对比实验、磁感应强度变化时的加工速度变化实验、随脉冲宽度变化的加工速度实验、表面粗糙度实验、电极损耗量实验、磁场电火花复合加工正交实验分析、电流波形变化等实验，实验分析了影响磁场电火花小孔加工效率的因素，并且跟单一的电火花加工中的影响因数进行了比较，大量的实验数据和理论推导证明磁场电火花复合加工比传统的单一电火花加工的效率提高了20％～400％左右。由此我们知道磁场电火花复合加工有效的改善了单一电火花加工速度慢、小孔加工中排屑困难、加工不稳定、加工工件表面质量不高、电极易损耗等缺点，为进行下一步研究提出了设想，为磁场电火花小孔加工设备的研制打下了良好的基础。
With the development of science and technology, the requirements of many industries and departments, such as aviation、spaceflight、mechanism、electron、automobile、medical treatment、optics、mould、chemical-fibre、materials、light-industry etc, which request to process various complex superficial workpieces、various super exact、finishing and especial workpeces, becomes more and more. Aiming at the reqirements, it is difficult for traditional EDM to reach. Although, the traditional EDM can machine various hard cutting and complex superficial workpieces, the practical application is affected by the disadvantages, slow speed of machining, inconvenience of discharging chipping, instability of processing, electrode easy to waste. At present, the scholars and technicians of home and oversea have had some researches about finishing works molding, finishing mechanism and technics rules, which is affected by various energy effects by oneself form single magnetic force and EDM and ultrasonic energy. The moulding machine-tools have been applied. The mechanics and EDM、EDM and ultrasonic、magnetic and electric chemistry compound machining etc, two energy compound machining, have respective characteristics and advantages, in the mean time have also respective shortages. But, magnetic and EDM compound machining isn't still covered. However, magnetic, and EDM compound machining can achieve predominancecomplement, remarkably boost the processing efficiency, improve superficial quality and markedly amend the defects of EDM by oneself.
This paper presented the research and exploration of mechanism and technics as well as the design of the magnetic circuit of this new compound machining, based on above, establishing the parameter model, meantime, analyzing influential effects on productivity of magnetic and EDM compound machining the holes through large numbers of experiments, including velcoity contrast experiments of pre-compound and after-compound machining with the change of current, velcoity contrast experiments of pre-compound and after-compound machining with the change of magnetic induction, velcoity contrast experiments of pre-compound and after-compound machining with the change of impulse width, experiments of the superficial roughness, experiments of the Electrode wastage, and intersectant experiments analysis as well as the change experiments of current waveforms. Through a number of experiments we analysed the influential effects of magnetic and EDM compound machining, compared the factors with EDM by oneself. A large of experiment records and deducibility have demonstrated that the productivity of magnetic and EDM compound machining is developed by 20%～400% than traditional EDM. By doing so, we can includede that the magnetic and EDM compound machining can effectively meliorate the shortcomings of single EDM, such as the slow speed of machining, inconvenience of discharging chipping、instability of processing, electrode easy to waste. It put forward the assumption for the next research, and pave a well way for the hole equipment of magnetic and EDM compound machining which will be developed。
本论文对磁场电火花复合加工这种新的复合加工的机理、工艺和复合加工的磁路设计进行了研究和探索，在此基础上，建立了磁场电火花复合加工的参数模型，同时通过大量的随着电流变化磁场电火花复合前后加工速度对比实验、磁感应强度变化时的加工速度变化实验、随脉冲宽度变化的加工速度实验、表面粗糙度实验、电极损耗量实验、磁场电火花复合加工正交实验分析、电流波形变化等实验，实验分析了影响磁场电火花小孔加工效率的因素，并且跟单一的电火花加工中的影响因数进行了比较，大量的实验数据和理论推导证明磁场电火花复合加工比传统的单一电火花加工的效率提高了20％～400％左右。由此我们知道磁场电火花复合加工有效的改善了单一电火花加工速度慢、小孔加工中排屑困难、加工不稳定、加工工件表面质量不高、电极易损耗等缺点，为进行下一步研究提出了设想，为磁场电火花小孔加工设备的研制打下了良好的基础。
With the development of science and technology, the requirements of many industries and departments, such as aviation、spaceflight、mechanism、electron、automobile、medical treatment、optics、mould、chemical-fibre、materials、light-industry etc, which request to process various complex superficial workpieces、various super exact、finishing and especial workpeces, becomes more and more. Aiming at the reqirements, it is difficult for traditional EDM to reach. Although, the traditional EDM can machine various hard cutting and complex superficial workpieces, the practical application is affected by the disadvantages, slow speed of machining, inconvenience of discharging chipping, instability of processing, electrode easy to waste. At present, the scholars and technicians of home and oversea have had some researches about finishing works molding, finishing mechanism and technics rules, which is affected by various energy effects by oneself form single magnetic force and EDM and ultrasonic energy. The moulding machine-tools have been applied. The mechanics and EDM、EDM and ultrasonic、magnetic and electric chemistry compound machining etc, two energy compound machining, have respective characteristics and advantages, in the mean time have also respective shortages. But, magnetic and EDM compound machining isn't still covered. However, magnetic, and EDM compound machining can achieve predominancecomplement, remarkably boost the processing efficiency, improve superficial quality and markedly amend the defects of EDM by oneself.
This paper presented the research and exploration of mechanism and technics as well as the design of the magnetic circuit of this new compound machining, based on above, establishing the parameter model, meantime, analyzing influential effects on productivity of magnetic and EDM compound machining the holes through large numbers of experiments, including velcoity contrast experiments of pre-compound and after-compound machining with the change of current, velcoity contrast experiments of pre-compound and after-compound machining with the change of magnetic induction, velcoity contrast experiments of pre-compound and after-compound machining with the change of impulse width, experiments of the superficial roughness, experiments of the Electrode wastage, and intersectant experiments analysis as well as the change experiments of current waveforms. Through a number of experiments we analysed the influential effects of magnetic and EDM compound machining, compared the factors with EDM by oneself. A large of experiment records and deducibility have demonstrated that the productivity of magnetic and EDM compound machining is developed by 20%～400% than traditional EDM. By doing so, we can includede that the magnetic and EDM compound machining can effectively meliorate the shortcomings of single EDM, such as the slow speed of machining, inconvenience of discharging chipping、instability of processing, electrode easy to waste. It put forward the assumption for the next research, and pave a well way for the hole equipment of magnetic and EDM compound machining which will be developed。
引文
[1] 赵万生主编，刘晋春主审，电火花加工技术，哈尔滨工业大学出版社，2000．5
[2] 杨世春．表面质量与光整技术[M]．北京：机械工业出版社，1999：1622232．
[3] 卢存伟，电火花加工工艺学，国防工业出版社，1998
[4] 刘晋春，陆纪赔，特种加工，北京：机械工业出版社，1992．11～27
[5] 李明辉，电火花加工理论基础，国防工业出版社，1989．1
[6] 郑少华，姜奉华编著，试验设计与数据处理，中国建材工业出版社，2004．3
[7] 张容发，用正交实验法选择磨削滚子端面的最佳参数，机械工艺师，1993，(12)：21～22
[8] 霍孟友，王永华，艾兴，对电火花加工技术发展过程的思考，山东大学学报 1998．4，89～91
[9] 刘晋春，赵家齐，赵万生主编，特种加工，机械工业出版社，1999．5
[10] 王高雄，常微分方程[M]．北京：高教出版社，1983．
[11] 成大先，机械实际手册(第1，2，3卷)，化学工业出版社，1993．1
[12] 孟有鸿，当前国内外电火花加工小孔近况，电加工，1994．1：17～18
[13] JD 杰克逊著，朱培豫译．经典电动力学[M]．北京：人民教育出版社，1980
[14] 欧红叶，胡先权，在均匀电磁场中带电粒子的相对论运动分析，江西师范大学报，2004．8，341～342
[15] 陶琳，电磁场中带电粒子束运动的力学模拟，曲阜师范大学学报，2004．10：65～67
[16] 秦曾煌．电工学(中册)[M]．北京：人民教育出版社，1981：2872302．
[17] 曹明让，张银喜，磁性研磨装置的磁路电路设计及研究，太原理工大学学报，2002．5：257～259
[18] 全泽松．电磁场理论[M]．成都：电子科技大学出版社，1995．
[19] 王以真，实用磁路设计，天津科学技术出版社，1991
[20] 程守洙，江之永．普通物理学[M]．第5版．北京：高教出版社，1998．
[21] 张勤河，超声振动辅助气中放电加工技术及其机理研究：[博士论文]济南：山东大学，2003。
[22] 林其壬，赵佑民，磁路设计原理，机械工业出版社，1987
[23] 徐明刚，张建华，张勤河，李丽，任升峰，超声振动辅助气体介质电火花加工机理研究，电加工与模具，2005．6
[24] H.C.Tsai,B.H.Yan,F.Y.Huang,EDM performance of Cr/Cubased composite electrodes,International Journal of Machine Tool and Manufacture 43(2003) 245-252
[25] J. C. Rebelo M. Kornmeier A. C. Batista A. M. Dias, Residual stress after EDM-FEM study and measurement results, 6th European Conference on Residual Stresses (ECRS6), 2002, p.159-164
[26] C.C.Wang,B.H.Yan,Blind hole drilling or A12O3/6601Alcomposite using rotary electro-discharge machining ,Journal of Materials Processing Technology 102(2000)90-102.
[27] J.X.Deng T.C.Lee, Techniques for improved surface integrity of electro-dischange machined ceramic composites, Surface Engineering, V.16,n0.5, p.411-414
[28] C.T. Yang S.S. Ho B.H. Yan, Micro Hole machining of Borosilicate Glass through Electrochemical Discharge Machining (ECDM), Precision machining of Advanced Materials, Volume 196 (2001), V.196, 2001, p.149-166
[29] G. Ya H.W. Qin Y.W. Xu, An Experimental Investigation on Rotary ultrasonic machining, Key Engineering Materials, Quanzhou, China, June 2-6, 2001, Volumes 202-203(2001), V.202-203,2001, 2001, p.277-280
[30] Q.H.Zhang, R.Du, J.H.Zhang, Q.B.Zhang, An investigation of ultrasonic-assisted electrical discharge machining in gas ,International Journal of Machine Tools& Manufacture 46(2006) 1582-1588.
[2] 杨世春．表面质量与光整技术[M]．北京：机械工业出版社，1999：1622232．
[3] 卢存伟，电火花加工工艺学，国防工业出版社，1998
[4] 刘晋春，陆纪赔，特种加工，北京：机械工业出版社，1992．11～27
[5] 李明辉，电火花加工理论基础，国防工业出版社，1989．1
[6] 郑少华，姜奉华编著，试验设计与数据处理，中国建材工业出版社，2004．3
[7] 张容发，用正交实验法选择磨削滚子端面的最佳参数，机械工艺师，1993，(12)：21～22
[8] 霍孟友，王永华，艾兴，对电火花加工技术发展过程的思考，山东大学学报 1998．4，89～91
[9] 刘晋春，赵家齐，赵万生主编，特种加工，机械工业出版社，1999．5
[10] 王高雄，常微分方程[M]．北京：高教出版社，1983．
[11] 成大先，机械实际手册(第1，2，3卷)，化学工业出版社，1993．1
[12] 孟有鸿，当前国内外电火花加工小孔近况，电加工，1994．1：17～18
[13] JD 杰克逊著，朱培豫译．经典电动力学[M]．北京：人民教育出版社，1980
[14] 欧红叶，胡先权，在均匀电磁场中带电粒子的相对论运动分析，江西师范大学报，2004．8，341～342
[15] 陶琳，电磁场中带电粒子束运动的力学模拟，曲阜师范大学学报，2004．10：65～67
[16] 秦曾煌．电工学(中册)[M]．北京：人民教育出版社，1981：2872302．
[17] 曹明让，张银喜，磁性研磨装置的磁路电路设计及研究，太原理工大学学报，2002．5：257～259
[18] 全泽松．电磁场理论[M]．成都：电子科技大学出版社，1995．
[19] 王以真，实用磁路设计，天津科学技术出版社，1991
[20] 程守洙，江之永．普通物理学[M]．第5版．北京：高教出版社，1998．
[21] 张勤河，超声振动辅助气中放电加工技术及其机理研究：[博士论文]济南：山东大学，2003。
[22] 林其壬，赵佑民，磁路设计原理，机械工业出版社，1987
[23] 徐明刚，张建华，张勤河，李丽，任升峰，超声振动辅助气体介质电火花加工机理研究，电加工与模具，2005．6
[24] H.C.Tsai,B.H.Yan,F.Y.Huang,EDM performance of Cr/Cubased composite electrodes,International Journal of Machine Tool and Manufacture 43(2003) 245-252
[25] J. C. Rebelo M. Kornmeier A. C. Batista A. M. Dias, Residual stress after EDM-FEM study and measurement results, 6th European Conference on Residual Stresses (ECRS6), 2002, p.159-164
[26] C.C.Wang,B.H.Yan,Blind hole drilling or A12O3/6601Alcomposite using rotary electro-discharge machining ,Journal of Materials Processing Technology 102(2000)90-102.
[27] J.X.Deng T.C.Lee, Techniques for improved surface integrity of electro-dischange machined ceramic composites, Surface Engineering, V.16,n0.5, p.411-414
[28] C.T. Yang S.S. Ho B.H. Yan, Micro Hole machining of Borosilicate Glass through Electrochemical Discharge Machining (ECDM), Precision machining of Advanced Materials, Volume 196 (2001), V.196, 2001, p.149-166
[29] G. Ya H.W. Qin Y.W. Xu, An Experimental Investigation on Rotary ultrasonic machining, Key Engineering Materials, Quanzhou, China, June 2-6, 2001, Volumes 202-203(2001), V.202-203,2001, 2001, p.277-280
[30] Q.H.Zhang, R.Du, J.H.Zhang, Q.B.Zhang, An investigation of ultrasonic-assisted electrical discharge machining in gas ,International Journal of Machine Tools& Manufacture 46(2006) 1582-1588.