电火花加工加工屑和气泡的运动及实现高效加工的控制方法研究
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摘要
电火花加工中,极间间隙内的加工屑浓度和气泡体积对加工稳定性和效率具有重要影响。研究极间间隙内加工屑和气泡的运动规律和机理,可以为控制电火花加工参数,使极间间隙内的加工屑浓度和气泡体积保持在合适的范围内,进而实现高效加工提供理论依据。然而,由于难以观察极间间隙内的现象,迄今为止,对加工屑和气泡的运动规律和机理的了解并不充分。
针对这一问题,本论文通过对连续放电和抬刀过程极间间隙内流场进行三维的液-气-固三相流仿真计算,来研究极间间隙内加工屑和气泡的运动规律和机理。结果发现,连续放电过程中,剧烈扩展的气泡是排除底面间隙加工屑的主要因素,但当气泡扩展到侧面间隙出口后,其排除底面间隙加工屑的能力减弱；抬刀过程中,抬刀高度必须大于某一值,才能将足够体积的清澈电火花加工油吸入底面间隙,消除加工屑在底面间隙的聚集,并且使底面间隙内的电火花加工油维持较长时间的运动从而将气泡带出底面间隙；抬刀速度必须大于某一值,才能使吸入底面间隙的清澈电火花加工油与底面间隙中的加工屑充分混合,有效消除底面间隙中加工屑的聚集,并且使底面间隙中的气泡偏离底面间隙中心而排出底面间隙。同时论文通过仿真计算,研究了电极加工时间、抬刀高度和抬刀速度对底面间隙内加工屑浓度和气泡体积的影响规律。结果发现,底面间隙中加工屑浓度和气泡体积随电极加工时间的增加而增加；抬刀高度和速度较小时,抬刀过程很难排除底面间隙内的气泡,底面间隙内加工屑浓度随加工的进行而迅速增加,抬刀高度和速度大于某一值后,抬刀过程能够将大部分气泡排出底面间隙,底面间隙内加工屑浓度随加工的进行稳定在某一值附近。
为验证仿真计算结果的正确性,论文利用透明材料搭建了实验装置,通过这些装置观察了连续放电和抬刀过程极间间隙内加工屑和气泡的运动情况。
最后,论文根据抬刀速度对底面间隙加工屑浓度和气泡体积的影响规律,提出了大抬刀速度对加工有利的观点；以电极加工时间对底面间隙加工屑浓度和气泡体积的影响规律为依据,结合实验结果分析,提出了寻找某一深度和抬刀高度下的最优电极加工时间的算法,在此基础上,根据抬刀高度对底面间隙加工屑浓度和气泡体积的影响规律,结合实验结果分析,提出了寻找某一深度下抬刀高度和电极加工时间最优组合的算法；最终,提出了电火花加工过程中实时调整抬刀高度和电极加工时间,使这两个参数在各加工深度下保持最优组合,实现高效加工的控制方法。
Debris concentration and bubble volume in bottom gap has a significant influence on the stability and efficiency of electrical discharge machining (EDM). The work of analyzing the mechanism of debris and bubble movements will provide the theoretical basis for controlling the parameters of EDM to keep a proper value of the debris concentration and bubble volume in bottom gap and to realize high efficiency machining. However, to date, this mechanism has not been fully understood because of the difficulty in observing debris and bubble movements in gap.
For solving the problem, the current study conducted three-dimension and gas-liquid-solid three-phase flow simulations for gap during consecutive pulse discharge process and electrode jump process of EDM respectively. The results showed that, during the consecutive discharge process, bubble expansion was the main factor of excluding debris from bottom gap, but the function became weak when there was bubble came out of the side gap; during the electrode jump process, the electrode jump height must be larger than a certain value to absorb enough clean oil into the bottom gap to effectively eliminate the aggregation of debris, and to keep the oil moving for a relative long time to push the bubble out of the bottom gap; the electrode jump speed must be larger than a certain value to make the absorbed clean oil mix well with the debris in bottom gap to effectively eliminate the concentration of debris, and to make the bubble departure from the bottom center and therefore move out of the bottom gap. The influence of electrode machining time, electrode jump height and electrode jump speed on the debris concentration and bubble volume in the bottom gap was analyzed through simulation. The results showed that the debris concentration and bubble volume increased along with the electrode machining time; when the electrode jump height and speed were low, the debris concentration increased quickly as the machining went on, and it was difficult to remove bubble out of the bottom gap; when the electrode jump height and speed were larger than a certain value, the debris concentration in bottom gap was almost constant, and most of the bubble was removed out of the bottom gap.
In order to verify the correctness of the simulation results, debris and bubble movements in gap during EDM was observed through a series of experimental devices which contained transparent materials.
According to the influence of electrode jump speed on the debris concentration and bubble volume in bottom gap, the opinion that the large electrode jump speed was beneficial for machining was suggested. On the basis of the influence of the electrode machining time on the debris concentration and bubble volume in bottom gap, combining with experiment, an algorithm of searching for optimal electrode machining time of a certain depth and electrode jump height was put forward. According to the influence of electrode jump height on the debris concentration and bubble volume in bottom gap, an algorithm of searching for the optimal combination of electrode jump speed and electrode machining time at a certain depth was provided. Finally, the strategy of timely adjusting the electrode jump height and electrode machining time to the optimal combination at each depth to realize high efficiency machining was proposed.
针对这一问题,本论文通过对连续放电和抬刀过程极间间隙内流场进行三维的液-气-固三相流仿真计算,来研究极间间隙内加工屑和气泡的运动规律和机理。结果发现,连续放电过程中,剧烈扩展的气泡是排除底面间隙加工屑的主要因素,但当气泡扩展到侧面间隙出口后,其排除底面间隙加工屑的能力减弱；抬刀过程中,抬刀高度必须大于某一值,才能将足够体积的清澈电火花加工油吸入底面间隙,消除加工屑在底面间隙的聚集,并且使底面间隙内的电火花加工油维持较长时间的运动从而将气泡带出底面间隙；抬刀速度必须大于某一值,才能使吸入底面间隙的清澈电火花加工油与底面间隙中的加工屑充分混合,有效消除底面间隙中加工屑的聚集,并且使底面间隙中的气泡偏离底面间隙中心而排出底面间隙。同时论文通过仿真计算,研究了电极加工时间、抬刀高度和抬刀速度对底面间隙内加工屑浓度和气泡体积的影响规律。结果发现,底面间隙中加工屑浓度和气泡体积随电极加工时间的增加而增加；抬刀高度和速度较小时,抬刀过程很难排除底面间隙内的气泡,底面间隙内加工屑浓度随加工的进行而迅速增加,抬刀高度和速度大于某一值后,抬刀过程能够将大部分气泡排出底面间隙,底面间隙内加工屑浓度随加工的进行稳定在某一值附近。
为验证仿真计算结果的正确性,论文利用透明材料搭建了实验装置,通过这些装置观察了连续放电和抬刀过程极间间隙内加工屑和气泡的运动情况。
最后,论文根据抬刀速度对底面间隙加工屑浓度和气泡体积的影响规律,提出了大抬刀速度对加工有利的观点；以电极加工时间对底面间隙加工屑浓度和气泡体积的影响规律为依据,结合实验结果分析,提出了寻找某一深度和抬刀高度下的最优电极加工时间的算法,在此基础上,根据抬刀高度对底面间隙加工屑浓度和气泡体积的影响规律,结合实验结果分析,提出了寻找某一深度下抬刀高度和电极加工时间最优组合的算法；最终,提出了电火花加工过程中实时调整抬刀高度和电极加工时间,使这两个参数在各加工深度下保持最优组合,实现高效加工的控制方法。
Debris concentration and bubble volume in bottom gap has a significant influence on the stability and efficiency of electrical discharge machining (EDM). The work of analyzing the mechanism of debris and bubble movements will provide the theoretical basis for controlling the parameters of EDM to keep a proper value of the debris concentration and bubble volume in bottom gap and to realize high efficiency machining. However, to date, this mechanism has not been fully understood because of the difficulty in observing debris and bubble movements in gap.
For solving the problem, the current study conducted three-dimension and gas-liquid-solid three-phase flow simulations for gap during consecutive pulse discharge process and electrode jump process of EDM respectively. The results showed that, during the consecutive discharge process, bubble expansion was the main factor of excluding debris from bottom gap, but the function became weak when there was bubble came out of the side gap; during the electrode jump process, the electrode jump height must be larger than a certain value to absorb enough clean oil into the bottom gap to effectively eliminate the aggregation of debris, and to keep the oil moving for a relative long time to push the bubble out of the bottom gap; the electrode jump speed must be larger than a certain value to make the absorbed clean oil mix well with the debris in bottom gap to effectively eliminate the concentration of debris, and to make the bubble departure from the bottom center and therefore move out of the bottom gap. The influence of electrode machining time, electrode jump height and electrode jump speed on the debris concentration and bubble volume in the bottom gap was analyzed through simulation. The results showed that the debris concentration and bubble volume increased along with the electrode machining time; when the electrode jump height and speed were low, the debris concentration increased quickly as the machining went on, and it was difficult to remove bubble out of the bottom gap; when the electrode jump height and speed were larger than a certain value, the debris concentration in bottom gap was almost constant, and most of the bubble was removed out of the bottom gap.
In order to verify the correctness of the simulation results, debris and bubble movements in gap during EDM was observed through a series of experimental devices which contained transparent materials.
According to the influence of electrode jump speed on the debris concentration and bubble volume in bottom gap, the opinion that the large electrode jump speed was beneficial for machining was suggested. On the basis of the influence of the electrode machining time on the debris concentration and bubble volume in bottom gap, combining with experiment, an algorithm of searching for optimal electrode machining time of a certain depth and electrode jump height was put forward. According to the influence of electrode jump height on the debris concentration and bubble volume in bottom gap, an algorithm of searching for the optimal combination of electrode jump speed and electrode machining time at a certain depth was provided. Finally, the strategy of timely adjusting the electrode jump height and electrode machining time to the optimal combination at each depth to realize high efficiency machining was proposed.
引文
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