壁槽电极雾化烧蚀成形加工工艺
|
摘要
为解决放电雾化烧蚀成形加工盲型孔过程中出现的烧蚀颗粒大、排屑难、加工不稳定问题,制作了中空铜管与正方形紫铜块相结合的成形电极,分别对无壁槽电极和壁槽电极的极间流场及颗粒质量浓度分布进行了仿真分析与比较,基于极间流场仿真结果进行了雾化烧蚀对比实验,并对两种电极加工工件表面形貌进行了对比分析。实验结果表明:当槽宽为1 mm、倾斜角为60°时,烧蚀效率最高。在相同加工条件下进行雾化烧蚀加工时,与无壁槽电极相比,壁槽电极的蚀除速率提高了15.7%,壁槽电极的电极相对损耗率增大了6.2%。壁槽电极加工时的表面质量比无壁槽电极加工时的表面质量高。实验结果验证了仿真结果的正确性。
In order to solve the problems of large scale of ablation particles, the chip removal difficulty and processing instability in the processes of atomizing discharge ablation forming blind holes, the forming electrodes of hollow copper pipes combined with the square copper billets were made. The simulation analyses and comparisons of the flow field and particle concentration distribution for without wall slot electrodes and with the wall slot electrodes were carried out respectively. The atomizing electrode ablation experiments were carried out based on the flow field simulation results. And the surface topographies of the workpieces machined by two type electrodes were compared and analyzed. The experimental results show that when the slot width is as 1 mm, the slope angle is as 60°, the ablation efficiency is the highest. Under the same atomization ablation processing conditions, compared with the without wall slot electrodes, the removal rate of with wall slot electrodes increases by 15.7%, the relative loss rate of with wall slot electrodes increases by 6.2%. The surface quality of the with wall slot electrodes is better than that of without wall slot electrodes. The experimental results were verified the correctness of the simulation results.
In order to solve the problems of large scale of ablation particles, the chip removal difficulty and processing instability in the processes of atomizing discharge ablation forming blind holes, the forming electrodes of hollow copper pipes combined with the square copper billets were made. The simulation analyses and comparisons of the flow field and particle concentration distribution for without wall slot electrodes and with the wall slot electrodes were carried out respectively. The atomizing electrode ablation experiments were carried out based on the flow field simulation results. And the surface topographies of the workpieces machined by two type electrodes were compared and analyzed. The experimental results show that when the slot width is as 1 mm, the slope angle is as 60°, the ablation efficiency is the highest. Under the same atomization ablation processing conditions, compared with the without wall slot electrodes, the removal rate of with wall slot electrodes increases by 15.7%, the relative loss rate of with wall slot electrodes increases by 6.2%. The surface quality of the with wall slot electrodes is better than that of without wall slot electrodes. The experimental results were verified the correctness of the simulation results.
引文
[1] 刘志东.特种加工[M].北京:北京大学出版社,2013.LIU Zhidong.Non-traditional Machining[M].Beijing:Beijing University Press,2013.
[2] KUNLEDA M,MIYOSHI Y,TAKAYA T,et al.High Speed 3D Milling by Dry EDM[J].CIRP Annals:Manufacturing Technology,2003,52(1):147-150.
[3] 汤传建,康小明,赵万生,等.液中喷气电火花加工试验研究[J] .电加工与模具,2008(3):16-20.TANG Chuanjian,KANG Xiaoming,ZHAO Wansheng,et al.Research on the Processing of Jet EDM in Fluid [J].Electromachining Mould,2008(3):16-20.
[4] 顾琳,赵万生,张志华,等.喷雾电火花铣削加工及其机理的分析[J].电加工与模具,2006(2):1-4.GU Lin,ZHAO Wansheng,ZHANG Zhihua,et al.Analysis of the Machining Process and Its Mechanism of Spray Spark Machining [J].Electromachining Mould,2006(2) :1-4.
[5] 李磊,顾琳,赵万生.多孔内冲液集束电极电火花加工极间流场仿真及试验研究[J].电火花成形及微小孔加工技术,2009(3):167-173.LI lei,GU Lin,ZHAO Wansheng.Simulation and Experimental Study of the Electrode Electric Spark Machining of the Porous Internal Jet Liquid Cluster Electrode [J].Electric Spark Forming and Micro-hole Processing Technology,2009(3):167-173.
[6] 蒋毅,孔令蕾,金光远,等.多孔质电极电火花加工极间流场仿真[J].机床与液压,2016,44(1):147-151.JIANG Yi,KONG Linglei,JIN Guangyuan,et al.Simulation of Flow Field between Eletrodes in Prorous-electrode of Electrical Discharge Machiniag[J].Machine Tool & Hydraulics,2016,44(1):147-151.
[7] THOE T B,ASPINWALL D K,KILLEY N.Combined Ultrasonic and Electrical Discharge Machining of Ceramic Coated Nickel Alloy[J].Journal of Materials Processing Technology,1999,92/93:323-328.
[8] KREMER D,LEBRUN J L,HOSARI B,et al.Effects of Ultrasonic Vibrations on the Performances in EDM[J].CIRP Annals Manufacturing Technology,1989,38(1):199-202.
[9] 储召良.电极抬刀运动与电火花加工性能研究 [D].上海:上海交通大学,2013.CHU Zhaoliang.Research on the Performance of the Electrode Lifting Tool and Electrical Discharge Machining[D].Shanghai:Shanghai Jiao Tong University,2013.
[10] 刘志东.放电诱导可控烧蚀高效加工典型工艺方法[J].电加工与模具,2012(1):1-6.LIU Zhidong.Typical Process Method for the Efficient Machining of Controlled Ablation by Discharge Induction [J].Electromachining Mould,2012(1):1-6.
[11] LIU Zhidong,XU Anyang,QIU Mingbo,et al.Basic Study of Combustion-material Removal Process by Multi-function Electrode[J].Procedia CIRP,2013,6:64-70.
[12] XU Anyang,LIU Zhidong,LI Wenpei,et al.Study of High-efficiency Electrical Discharge Machining-induced Ablation Machining of Titanium Alloy TC4 Using a Multi-function Electrode[J].The International Journal of Advanced Manufacturing Technology,2014,72(1/4):377-385.
[13] LIU Zhidong,YIN Chunjing,CHENG Longhai,et al.Efficient Combined Machining of Electrospark-induced Controllable Combustion and Turning Dressing for TC4[J].Materials & Manufacturing Processes,2014,29(5):614-620.
[14] CAO Zhongli,LIU Zhidong,WANG Xiangzhi,et al.Monopulse Electrical Discharge Machining Ablation Drilling Technology for Ti-6Al-4V Titanium Alloy[J].The International Journal of Advanced Manufacturing Technology 2016,86(1/4):539-546.
[15] CAO Zhongli,LIU Zhidong,LING Jiajian,et al.Deep-type Hole Machining by Inner Jetted Aerosol Dielectric Ablation[J].The International Journal of Advanced Manufacturing Technology,2015,78 (9/12):1989-1998.
[16] KUMAR M M,NATARAJAN E .CFD Simulation for Two-phase Mixing in 2D Fluidized Bed[J].International Journal of Advanced Manufacturing Technology,2009,45:1-4.
[17] 李磊.集束电极电火花加工性能研究[D].上海:上海交通大学,2011.LI lei.Research on the Performance of Electric Spark Machining of Cluster Electrodes[D].Shanghai:Shanghai Jiao Tong University,2011.
[18] KOENIG W,WEILL R,WERTHEIM R,et al.The Flow Fields in the Working Gap with Electro-discharge-machining[J].Annals of the CIRP,1977,25(1):71-76.
[2] KUNLEDA M,MIYOSHI Y,TAKAYA T,et al.High Speed 3D Milling by Dry EDM[J].CIRP Annals:Manufacturing Technology,2003,52(1):147-150.
[3] 汤传建,康小明,赵万生,等.液中喷气电火花加工试验研究[J] .电加工与模具,2008(3):16-20.TANG Chuanjian,KANG Xiaoming,ZHAO Wansheng,et al.Research on the Processing of Jet EDM in Fluid [J].Electromachining Mould,2008(3):16-20.
[4] 顾琳,赵万生,张志华,等.喷雾电火花铣削加工及其机理的分析[J].电加工与模具,2006(2):1-4.GU Lin,ZHAO Wansheng,ZHANG Zhihua,et al.Analysis of the Machining Process and Its Mechanism of Spray Spark Machining [J].Electromachining Mould,2006(2) :1-4.
[5] 李磊,顾琳,赵万生.多孔内冲液集束电极电火花加工极间流场仿真及试验研究[J].电火花成形及微小孔加工技术,2009(3):167-173.LI lei,GU Lin,ZHAO Wansheng.Simulation and Experimental Study of the Electrode Electric Spark Machining of the Porous Internal Jet Liquid Cluster Electrode [J].Electric Spark Forming and Micro-hole Processing Technology,2009(3):167-173.
[6] 蒋毅,孔令蕾,金光远,等.多孔质电极电火花加工极间流场仿真[J].机床与液压,2016,44(1):147-151.JIANG Yi,KONG Linglei,JIN Guangyuan,et al.Simulation of Flow Field between Eletrodes in Prorous-electrode of Electrical Discharge Machiniag[J].Machine Tool & Hydraulics,2016,44(1):147-151.
[7] THOE T B,ASPINWALL D K,KILLEY N.Combined Ultrasonic and Electrical Discharge Machining of Ceramic Coated Nickel Alloy[J].Journal of Materials Processing Technology,1999,92/93:323-328.
[8] KREMER D,LEBRUN J L,HOSARI B,et al.Effects of Ultrasonic Vibrations on the Performances in EDM[J].CIRP Annals Manufacturing Technology,1989,38(1):199-202.
[9] 储召良.电极抬刀运动与电火花加工性能研究 [D].上海:上海交通大学,2013.CHU Zhaoliang.Research on the Performance of the Electrode Lifting Tool and Electrical Discharge Machining[D].Shanghai:Shanghai Jiao Tong University,2013.
[10] 刘志东.放电诱导可控烧蚀高效加工典型工艺方法[J].电加工与模具,2012(1):1-6.LIU Zhidong.Typical Process Method for the Efficient Machining of Controlled Ablation by Discharge Induction [J].Electromachining Mould,2012(1):1-6.
[11] LIU Zhidong,XU Anyang,QIU Mingbo,et al.Basic Study of Combustion-material Removal Process by Multi-function Electrode[J].Procedia CIRP,2013,6:64-70.
[12] XU Anyang,LIU Zhidong,LI Wenpei,et al.Study of High-efficiency Electrical Discharge Machining-induced Ablation Machining of Titanium Alloy TC4 Using a Multi-function Electrode[J].The International Journal of Advanced Manufacturing Technology,2014,72(1/4):377-385.
[13] LIU Zhidong,YIN Chunjing,CHENG Longhai,et al.Efficient Combined Machining of Electrospark-induced Controllable Combustion and Turning Dressing for TC4[J].Materials & Manufacturing Processes,2014,29(5):614-620.
[14] CAO Zhongli,LIU Zhidong,WANG Xiangzhi,et al.Monopulse Electrical Discharge Machining Ablation Drilling Technology for Ti-6Al-4V Titanium Alloy[J].The International Journal of Advanced Manufacturing Technology 2016,86(1/4):539-546.
[15] CAO Zhongli,LIU Zhidong,LING Jiajian,et al.Deep-type Hole Machining by Inner Jetted Aerosol Dielectric Ablation[J].The International Journal of Advanced Manufacturing Technology,2015,78 (9/12):1989-1998.
[16] KUMAR M M,NATARAJAN E .CFD Simulation for Two-phase Mixing in 2D Fluidized Bed[J].International Journal of Advanced Manufacturing Technology,2009,45:1-4.
[17] 李磊.集束电极电火花加工性能研究[D].上海:上海交通大学,2011.LI lei.Research on the Performance of Electric Spark Machining of Cluster Electrodes[D].Shanghai:Shanghai Jiao Tong University,2011.
[18] KOENIG W,WEILL R,WERTHEIM R,et al.The Flow Fields in the Working Gap with Electro-discharge-machining[J].Annals of the CIRP,1977,25(1):71-76.