基于MINITAB的旋转超声电解复合加工微小深孔试验研究
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摘要
为解决电解加工微小深孔中电解液难以进入加工区及电解产物难以排除的问题,搭建了内喷式旋转超声电解复合加工试验装置,并基于MINITAB开展了微小深孔侧面间隙的试验研究。试验结果表明,加工电压、阴极裸露长度、进给速度和阴极转速对侧面间隙影响显著,且前两者对侧面间隙产生负效应,后两者对侧面间隙产生正效应,加工电压*进给速度、加工电压*阴极转速、加工电压*阴极裸露长度、进给速度*阴极转速对侧面间隙的交互作用显著,并得到了侧面间隙的数学回归模型,试验值与回归模型的相对误差为8.18%。在此基础上对模型进行优化,进行了响应曲面试验,并通过试验进行验证。优化结果表明,试验值与优化模型值相对误差为4.96%。通过控制阴极伸出长度能有效地减小加工孔的锥度,理论上可以将孔的锥度减小至零。所加工的微小深孔直径为4.007mm,深为67.5mm,加工电流稳定。
In order to solve the difficulties of the electrolyte reaching into the machining area and the discharging of the products of the Electrochemical Machining( ECM) in the micro-deep machining by ECM,the device of the inner-jet Rotary Combined Ultrasonic and Electrochemical Marching( RCUECM) was built and the experiments on the side gap of the micro-deep holes was carried out based on the MANITAB. The results showed that there are significant effects on the side gap of the machining voltage,exposed length,feed rate and speed and there is negative effects of the first two parameters and positive effects of the last two parameters. The interactions of the machining voltage * feed rate,the machining voltage * speed,the machining voltage * exposed length and feed rate* speed are significant. The mathematical regression model of the side gap was gained from the experiments with 8. 18% relative error compared to the experimental value. To optimized the model,the response surface experiments was carried out and the verification tests with the optimized processing parameters was done. The results show that the relative error of the optimized model and the experimental value is only 4. 96%,which improved the reliability of the mathematical model. The taper of the holes is effectively reduced to zero by controlling the length of the extension of cathode theoretically. the micro-deep hole with diameter 4. 007 mm,depth 67. 5mm was processed at last and the machining current is stable which expressed that the difficulties of the electrolyte reaching into the machining area and the discharging of the products are solved in the micro-deep machining by the RUECM indirectly.
In order to solve the difficulties of the electrolyte reaching into the machining area and the discharging of the products of the Electrochemical Machining( ECM) in the micro-deep machining by ECM,the device of the inner-jet Rotary Combined Ultrasonic and Electrochemical Marching( RCUECM) was built and the experiments on the side gap of the micro-deep holes was carried out based on the MANITAB. The results showed that there are significant effects on the side gap of the machining voltage,exposed length,feed rate and speed and there is negative effects of the first two parameters and positive effects of the last two parameters. The interactions of the machining voltage * feed rate,the machining voltage * speed,the machining voltage * exposed length and feed rate* speed are significant. The mathematical regression model of the side gap was gained from the experiments with 8. 18% relative error compared to the experimental value. To optimized the model,the response surface experiments was carried out and the verification tests with the optimized processing parameters was done. The results show that the relative error of the optimized model and the experimental value is only 4. 96%,which improved the reliability of the mathematical model. The taper of the holes is effectively reduced to zero by controlling the length of the extension of cathode theoretically. the micro-deep hole with diameter 4. 007 mm,depth 67. 5mm was processed at last and the machining current is stable which expressed that the difficulties of the electrolyte reaching into the machining area and the discharging of the products are solved in the micro-deep machining by the RUECM indirectly.
引文
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[19]徐家文,云乃彰,王建业,等.电化学加工技术原理工艺及应用[M].北京:国防工业出版社,2008:34-90.
[20]赵雪松,高洪.精密模具超声电解复合抛光试验研究[J].农业机械学报,2004,35(3):188-190.
[21]朱永伟,王占和,云乃彰.超声电解复合微细加工装置与试验研究[J].机械科学与技术,2008,27(8):986-991.
[22]杨大春,云乃彰,严德荣.硬脆金属的超声电解复合加工研究[J].电加工与模具,2002(2):31-33.
[23]刘泽祥,康敏,陶晓明.超声电解复合加工装置的振动系统优化设计[J].中国机械工程,2014,25(6):761-765.
[24]洪楠,侯军,李志辉.MINITAB统计分析教程[M].北京:电子工业出版社,2007.
[25]程敬丽,郑敏,楼建晴.常见的试验优化设计方法对比[J].实验室研究与探索,2012,31(7):7-11.
[26]BILGI D S,KUMAR R,JAIN V K,et al.Predicting radial overcut in deep holes drilled by shaped tube electrochemical machining[J].Int J Adv Manuf Technol,2008(39):47-54.
[27]EBEID S J,HEWIDY M S,El-Taweel T A,et al.Towards higher accuracy for ECM hybridized with low-frequency vibrations using the response surface methodology[J].Journal of Materials Processing Technology,2004(149):432-438.
[28]DAYANAND S Bilgi,JAIN V K,SHEKHAR R,et al.Hole quality and interelectrode gap dynamics during pulse current electrochemical deep hole drilling[J].Int Adv Manuf Technol,2007(34):79-95.
[2]RAJURKAR K P,ZHU D,Mc Geough J A,et al.New Development in electrochemical machining[J].Ann.CIRP,1999,48(2):567-579.
[3]RAJURKAR K P,KOZAK J,WEI B.Study of pulse electrochemical machining characteristics[J].Ann.CIRP,1993,42(1):231-234.
[4]PA P S.Electrode Form Design of Large Holes of Die Material in Ultrasonic Electrochemical Finishing[J].Journal of Material Processing Technology,2007(192/193):470-477.
[5]李兆龙,狄士春.深小孔脉冲电解加工精度控制研究[J].兵工学报,2012,33(4):414-419.
[6]李红英,云乃彰,朱永伟.超声电解复合微细加工硬质合金试验研究[J].航空制造技术,2009(1):78-82.
[7]傅相林.超声对电化学过程的影响研究[D].扬州:扬州大学,2005.
[8]甘雪萍,戴曦,张传福.超声空化及其在电化学中的应用[J].四川有色金属,2001(3):24-27.
[9]程敬泉,姚素薇.超声波在电化学中的应用[J].电镀与精饰,2005,27(1):16-20.
[10]RUSZAJ A,ZYBURA M,ZUREK R,et al.Some aspects of the electrochemical machining process supported by electrode ultrasonic vibrations optimization[J].Proc.Instn Mech.Engrs Vol.217 Part B:J.Engineering Manufacture,2003(217):1365-1371.
[11]HEWIDY M S,EBEID S J,El-Taweel T A,et al.Modelling the performance of ECM assisted by low frequency vibration[J].Journal of Materials Processing Technology,2007(189):466-472.
[12]SEBASTIAN Skoczypiec.Research on ultrasonically assisted electrochemical machining process.www.Springerlink.com.
[13]BHATTACHARYYA B,MALAPATI M,MUNDA J,et al.Influence of tool vibration on machining performance in electrochemical micro-machining of Copper[J].International Journal of Machine Tools&Manufacture,2007(47):335-342.
[14]朱永伟,王占和,李红英,等.电解复合超声频振动微细加工机理与试验研究[J].中国机械工程,2008,19(15):1786-1792.
[15]艾冬梅,贾志新.小孔加工技术发展现状[J].机械工程师,2000(1):8-10.
[16]王峻.现代深孔加工技术[M].哈尔滨:哈尔滨工业大学出版社,2005.
[17]张祖军,陈奎儒,刘继光,等.深小孔特种加工[J].机械工程与自动化,2004(6):20-22.
[18]何英,朱红钢,韩野.航空发动机小孔特种加工技术[J].航空制造技术,2011(4):57-61.
[19]徐家文,云乃彰,王建业,等.电化学加工技术原理工艺及应用[M].北京:国防工业出版社,2008:34-90.
[20]赵雪松,高洪.精密模具超声电解复合抛光试验研究[J].农业机械学报,2004,35(3):188-190.
[21]朱永伟,王占和,云乃彰.超声电解复合微细加工装置与试验研究[J].机械科学与技术,2008,27(8):986-991.
[22]杨大春,云乃彰,严德荣.硬脆金属的超声电解复合加工研究[J].电加工与模具,2002(2):31-33.
[23]刘泽祥,康敏,陶晓明.超声电解复合加工装置的振动系统优化设计[J].中国机械工程,2014,25(6):761-765.
[24]洪楠,侯军,李志辉.MINITAB统计分析教程[M].北京:电子工业出版社,2007.
[25]程敬丽,郑敏,楼建晴.常见的试验优化设计方法对比[J].实验室研究与探索,2012,31(7):7-11.
[26]BILGI D S,KUMAR R,JAIN V K,et al.Predicting radial overcut in deep holes drilled by shaped tube electrochemical machining[J].Int J Adv Manuf Technol,2008(39):47-54.
[27]EBEID S J,HEWIDY M S,El-Taweel T A,et al.Towards higher accuracy for ECM hybridized with low-frequency vibrations using the response surface methodology[J].Journal of Materials Processing Technology,2004(149):432-438.
[28]DAYANAND S Bilgi,JAIN V K,SHEKHAR R,et al.Hole quality and interelectrode gap dynamics during pulse current electrochemical deep hole drilling[J].Int Adv Manuf Technol,2007(34):79-95.