摘要
随着技术的进步,对于各种尺寸的精密高效加工要求越来越高,对于尺度在2-O.1mm常规材料的形体加工,小尺寸的切削就可以应对,但是对于切削加工难以加工的硬脆材料,这就需要发明各种非传统加工方式来应对新的挑战。射流电解加工是射流加工和电解加工的复合加工。射流电解加工是以离子方式去除材料,理论上可以达到很高的加工精度。同时它加工的工件表面不存在任何冶金缺陷,因此射流电解加工在小尺寸加工方面有很大的应用前景。
射流电解加工以前主要用于打孔,本课题将利用射流电解进行窄槽加工,并研究其工艺规律,进一步实现三维形体的加工。主要有以下研究内容：
(1)本文作者研制了一种新的射流电解加工原理性样机,并且研制了玻璃喷嘴拉伸装置,使拉制的玻璃喷嘴最小内径达到Φ0.0033mm。
(2)本文作者对射流电解窄槽加工的工艺参数(如：电压、占空比、频率和喷嘴出口的流速)进行了研究,并对窄槽加工的成型规律进行了总结。射流电解加工时,喷嘴和工件之间就产生火花放电,此时加工的状态不太稳定,不能进行稳定加工。为了控制电火花的产生,以稳定加工状态,通过正交实验对电火花产生的各因素进行了考察,最终发现占空比对火花流速的影响比较显著,占空比越大越容易产生电火花。对不锈钢进行加工时,当喷嘴内径Φ0.67mm、靶距lmm、电压在450V-550V、占空比在50%-90%、频率500Hz-1500Hz时,金属的去除量稳定在4.1-10.15mg。作者通过对不锈钢加工后的槽形分析发现,工件一旦进入加工区就会被均匀加工,因此用截面为圆形的玻璃喷嘴加工时,窄槽的横截面呈现椭圆的形状,这就相当于一个椭圆球铣刀加工的效果。
(3)本文作者利用射流电解加工进行了二维雕刻,加工的最小的窄槽是0.05mm,并对射流电解加工槽形的建模进行了验证。
本文对射流电解加工窄槽的规律进行了探索,为射流电解小尺寸三维形体加工的研究奠定了基础。
As the trend towards miniaturization continues, there are many kinds nontraditional techniques are receiving to meet the needs of macro- to micro-scale machining. For the size between 2～0.1 mm machining, the traditional cutting method could be used for the general material but hard and brittle ones, new unconventional metal remove method should be invented to deal with it. The principle of the electrolyte machining is ion removing from the metal surface; it makes the possibility of high precision. Meanwhile Surface of workpiece which there is no metallurgical defects on, processing by electrolyte jet machining. Therefore, electrolyte jet machining has a great prospect, used in Small-size machining.
Electrolyte jet machining is mainly used for drilling hole before but the author of this paper processes narrow groove used it and study technological law. Further, the author machines three-dimensional shape, used it. The main research contents as following:
(1)The author of this paper has studied and developed a new electrolyte jet machining tools.the equipment for shaping the nozzle has been invented also, the internal diameter of the nozzle could beΦ0.0033mm.
(2)The parameters that machined narrow groove by electrolyte Jet machining are researched(such as voltage, duty cycle, frequency and velocity of nozzle exit is researched in the device).the law molded narrow groove is summarized.using electrolyte jet machining, spark discharge arises between the nozzle and the work piece, it makes the process can not be continued. In order to control the production of electric spark and stabilize the processing state, through orthogonal test i investigates various factors generated electric spark. I have found that duty cycle have significantly effect on Velocity produced spark.The more big duty cycle the easier producing spark. When diameter inside nozzle isΦ0.67mm, target distance is lmm, voltage varies from 450V to 550V, the frequency varies from 100 Hz to 1000 Hz, duty cycle varies from 10% to 90%, and the amount of metal remove varies from 4.1mg to 10.15mg. the author machines narrow groove on Stainless Steel. With the analysis the shape of groove, once a part of the work piece entered machining zone which was formed by jet, it will be evenly machined. Therefore the form of the cross-section of groove was machined is oval.In other words, it looked like cutting effect of an oval ball milling cutter.
(3)The author carried out two-dimensional.engraving using jet electrochemical machining.and the width of the groove can be fined to 0.05mm in the engrave.the model which study shape of groove is verified.
The law processed narrow groove, found in this papers is base studied for machining Small-size three-dimensional shape.
引文
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