超硬材料的超声电火花复合加工的试验研究
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摘要
超硬材料具有高硬度、高耐磨性等特点,使用传统的机械方法成型加工比较困难,而特种加工是加工这些超硬材料的有效方法。在难加工材料和精密加工中,超声加工技术具有普通加工无法比拟的工艺效果,将超声加工和电火花相结合进行复合加工,常常能大幅度地提高加工速度、改善加工质量和完成一般加工方法难以完成的加工工作。因此,被广泛地应用于国民经济的各部门,并有广阔的应用前景。
本文在理论上分析了超声电火花复合加工的加工机理及超硬合金、聚晶金刚石、导电陶瓷三种超硬材料的性能及用途。针对超硬材料的超声电火花复合加工试验,分析了超声振动对间隙放电状态、放电通道的形成的影响以及超声对放电凹坑、表面显微组织的影响。通过试验方案的设计,运用超声电火花法对这三种超硬材料进行加工,研究脉冲宽度、超声振幅、磨粒大小对加工效率的影响以及加工中电极的损耗情况。并进一步分析了电火花加工对超声加工的影响,并对超声电火花复合加工中的放电情况进行一定的分析。超声复合加工中的电火花放电是一个复杂的过程,电火花加工对超声加工的加工效率和加工精度有一定影响。试验结果表明材料的去除率随着脉冲宽度、超声振幅的增大而增大;加工表面粗糙度随着脉冲宽度、超声振幅的增大而增大,磨料颗粒的大小也影响了加工表面粗糙度。
Super-hard material has characteristics of high hardness and high wearability. It is difficult to machine it by the traditional mechanical method. Non-traditional machining is an effective way to process the super-hard material. In the difficult-to-cut material machining and precision machining, the ultrasonic machining technology has the effect that general processing technology can not match. The combination of ultrasonic machining and electrical discharge machining (EDM) can greatly improve the processing speed and quality. This technique can complete the processing work that general processing method can not finish. Therefore, it has been widely used in various national departments and has broad application prospects.
In this paper, the mechanism of ultrasonic hybrid EDM in super-hard material processing and the properties of super-hard alloy, polycrystalline diamond (PCD) and conductive ceramic are introduced. The effect of ultrasonic vibration on the gap discharge status, discharge channel and the surface microstructure is studied. A set of experiments are designed to machine the three kinds of super-hard material with ultrasonic hybird EDM. In this way, the impacts of pulse width, ultrasonic amplitude and abrasive size on the processing efficiency are obtained. The attrition of the electrode are also introduced here. The impact of EDM process on ultrasonic machining and the discharge situation are analyzed. The results show that EDM has some impact on the efficiency and accuracy of ultrasonic machining.The discharge of EDM in the experiment is a complex process.The results also show that the material removal rate increases if the pulse width and ultrasonic amplitude increase. Surface roughness becomes larger when the pulse width and ultrasonic amplitude increase. The size of abrasive particles also has a certain impact on the roughness.
本文在理论上分析了超声电火花复合加工的加工机理及超硬合金、聚晶金刚石、导电陶瓷三种超硬材料的性能及用途。针对超硬材料的超声电火花复合加工试验,分析了超声振动对间隙放电状态、放电通道的形成的影响以及超声对放电凹坑、表面显微组织的影响。通过试验方案的设计,运用超声电火花法对这三种超硬材料进行加工,研究脉冲宽度、超声振幅、磨粒大小对加工效率的影响以及加工中电极的损耗情况。并进一步分析了电火花加工对超声加工的影响,并对超声电火花复合加工中的放电情况进行一定的分析。超声复合加工中的电火花放电是一个复杂的过程,电火花加工对超声加工的加工效率和加工精度有一定影响。试验结果表明材料的去除率随着脉冲宽度、超声振幅的增大而增大;加工表面粗糙度随着脉冲宽度、超声振幅的增大而增大,磨料颗粒的大小也影响了加工表面粗糙度。
Super-hard material has characteristics of high hardness and high wearability. It is difficult to machine it by the traditional mechanical method. Non-traditional machining is an effective way to process the super-hard material. In the difficult-to-cut material machining and precision machining, the ultrasonic machining technology has the effect that general processing technology can not match. The combination of ultrasonic machining and electrical discharge machining (EDM) can greatly improve the processing speed and quality. This technique can complete the processing work that general processing method can not finish. Therefore, it has been widely used in various national departments and has broad application prospects.
In this paper, the mechanism of ultrasonic hybrid EDM in super-hard material processing and the properties of super-hard alloy, polycrystalline diamond (PCD) and conductive ceramic are introduced. The effect of ultrasonic vibration on the gap discharge status, discharge channel and the surface microstructure is studied. A set of experiments are designed to machine the three kinds of super-hard material with ultrasonic hybird EDM. In this way, the impacts of pulse width, ultrasonic amplitude and abrasive size on the processing efficiency are obtained. The attrition of the electrode are also introduced here. The impact of EDM process on ultrasonic machining and the discharge situation are analyzed. The results show that EDM has some impact on the efficiency and accuracy of ultrasonic machining.The discharge of EDM in the experiment is a complex process.The results also show that the material removal rate increases if the pulse width and ultrasonic amplitude increase. Surface roughness becomes larger when the pulse width and ultrasonic amplitude increase. The size of abrasive particles also has a certain impact on the roughness.
引文
[1]刘晋春,赵家齐特种加工(第2版),机械工业出版社,1996.
[2]赵万生.电火花加工技术.哈尔滨:哈尔滨工业大学出版社,2000.
[3]王爱玲,祝锡晶,吴秀玲.功率超声加工技术.北京:国防工业出版社,2007:42~61.
[4]张云电.超声加工及其应用.北京:国防工业出版社,1995:1~97,141~220.
[5]袁易全.近代超声原理与应用.南京:南京大学出版社,1996:24~71.
[6]范国良,陈传梁.超声加工概况和未来展望.电加工,1994(6):7~11.
[7]钱军,高长水.工件激振式复合电火花微细孔加工.航空精密制造技术.1997,33(5):18~20.
[8] Brian K.Rhoney, Albert J.Shih, Ronald O.Scattergood, etal. Wire electrical discharge machining of metal bond diamond Wheels for ceramict grinding. International Journal of Machine Tools & Manufacture. 2002(42) :1355~1362.
[9] Yu Zuyuan, Masuzawa, Takahisa, Fujino M. 3D micro-EDM with simple shape electrode. Part 1: Machining of cavities with sharp corners and electrode wear compensation. International Journal of Electrical Machining, 1998(3) :7~12.
[10] Heath.P.J. Developments in applications of PCD tooling [J] .Journal of Materials Processing Technology 2001(11) :31~38.
[11] Philip Koshy, V.K. Jain, G.K. Lal. Grinding of cemented carbide with electrical spark assistance. Journal of Materials Processing Technology 1997(72):61~68.
[12] H. Juhr, H.-PSchulze, G. Wollenberg, K.Kunanza. Improved cemented carbide properties after wire-EDM by pulse shaping. Journal of Materials Processing Technology 2004(149): 178~183
[13] S.H. Lee, X.P. Li. Study of the effect of machining parameters on the machining characteristics in electrical discharge machining of tungsten carbide. Journal of Materials Processing Technology. 2001(115): 344~358.
[14]程学艳.超声波机床及其发展.新技术新工艺,2004(10):40~43.
[15]艾枫.一种新颖的超声振动加工技术.制造技术与机床,2007(3):25~27.
[16]郭钟宁等.难加工材料的超声电火花线切割复合加工工艺研究.电加工与具.2001(2):39~41.
[17]曹凤国,张勤俭.超硬材料的特种加工技术.新材料产业,2006(10):47~51.
[18]霍孟友,艾兴,张建华.超硬材料研究及展望.机械工艺师.1998(12):20~24.
[19]郭钟宁.超声线切割复合加工技术的研究实验.机械加工与自动化.2001(7):30~31.
[20]王贵成,张银喜.精密与特种加工.武汉理工大学出版社,2001.
[21]周曦亚,罗博.金属与超硬材料复合的研究.材料导报.2007(11):447~449.
[22]张勤俭,曹凤国,等.聚晶金刚石加工技术进展.金刚石与磨料磨具工程2006(4):76~80.
[23]冯彩梅,王为民,傅正义.可加工陶瓷材料及其制造技术的研究进展.武汉理工大学学报2004(5):35~37.
[24]康新龙.电火花复合加工原理及应用.机电产品开发与创新,2007(7):175~177.
[25]袁松梅,赵万生,等.超声电火花复合加工的研究进展.航空精密制造技术,1998(6):17~20.
[26]陈桂生.超声换能器设计.北京:海洋出版社,1984:10~81.
[27]袁易全.超声换能器.南京:南京大学出版社,1992:270~306.
[28]张云电.夹心式压电换能器及其应用.北京:科学出版设,2006(1) :59~79,103~107.
[29]曹白杨,董平,韩文仲,等.功率超声换能器应用与设计.华北航天工业学院学报,2000,10(2):24~27.
[30] L EMASTER R A,GRAFF K F.Influence of ceramic location on high power transducer performance.IEEE Ultrasonic Symposium Proceedings,1978:296~299.
[31] Eiji MORI.Ultrasonics International 89 Conference Proceedings:256.
[32] Kleesattel C.Uniform Stress Contours for Disk and Ring Resonators Bibrating in axially symmetric radial and torsional modes.Acustica,968,20:1~13.
[33] K W Klontz,D M Divan.Contactless power delivery system for mining applications.IEEE Trans. on Industry Applications,1995,31(1):27~35.
[34] Andrea Cardoni,Margaret Lucas.Enhanced vibration performance of ultrasonic block horns.Ultrasonics,2002,40:365~369.
[35] MOFFETT M B.Characterization of Terfenol-D for magnetost rictive transducers.J Acoust Soc Am,1991,89(3):1448~1455.
[36]林书玉.超声换能器的原理与设计.北京:科学出版社,2004:95~100,239~242.
[37]贺西平,程存弟.几种常见形状函数超声变幅杆性能参量的同意表达.陕西师范大学学报(自然科学版),1994(3):29~32.
[38]贺西平,高洁.超声变幅杆设计方法综述.声学技术,2006,25(1) :82~86.
[39] Yuji Watanabe.A study on a transducer-stepped type solid horn system for flexural mode ultrasonic high powertransducer with one dimensional construction.Ultrasonics International 91 Conference Proceedings,1991(34):435~438.
[40] Yuji Watanabe,Eiji Mori.A study on a new flexural-mode transducer-solid horn system and itsapplication to ultrasonic plastics welding.Ultrasonics,1996(34):235~238.
[41] Eiji MORI,Masami UNO.Analysis of torsional vibration of an ultrasonic exponential solid horn with a tool and its design considering fatigue limit.Bulletin of the Tokyo institute of technology,1963(51):63~80.
[42]苏达士等.超声加工与放电加工的几种复合加工方式.轻工机械.2004(3):75~77.
[43]袁松梅.小型超声电火花复合加工系统的研究,[博士学位论文].哈尔滨:哈尔滨工业大学,2000.11.
[44]徐明刚.超声振动-气体介质电火花复合加工技术及机理研究,[博士学位论文].山东:山东大学,2007.7.
[45]曹明让,杨世春,等.超声电火花复合加工速度工艺试验研究.新技术新工艺.2007(3):22~23.
[46] M.Komarala.超声加工表面粗糙度和精度的研究.国外金属加工.1990(1):1~6.
[47]郝建华,倪振文.超声加工工具材料硬度对其磨损影响的研究.电加工.1999(30):22~24.
[48]贾志新,张建华,艾兴.超声频间隙脉冲放电加工的放电特性和加工特性的理论研究.电加工,1994(6):25~28.
[49]竺志大,王占和,范仲俊.超声复合微细电火花加工机理与试验.新技术新工艺,2009(1):76~80.
[50]冯平法,郑书友,张京京.功率超声加工关键技术的研究进展.制造技术与机床,2009(5):57~62.
[2]赵万生.电火花加工技术.哈尔滨:哈尔滨工业大学出版社,2000.
[3]王爱玲,祝锡晶,吴秀玲.功率超声加工技术.北京:国防工业出版社,2007:42~61.
[4]张云电.超声加工及其应用.北京:国防工业出版社,1995:1~97,141~220.
[5]袁易全.近代超声原理与应用.南京:南京大学出版社,1996:24~71.
[6]范国良,陈传梁.超声加工概况和未来展望.电加工,1994(6):7~11.
[7]钱军,高长水.工件激振式复合电火花微细孔加工.航空精密制造技术.1997,33(5):18~20.
[8] Brian K.Rhoney, Albert J.Shih, Ronald O.Scattergood, etal. Wire electrical discharge machining of metal bond diamond Wheels for ceramict grinding. International Journal of Machine Tools & Manufacture. 2002(42) :1355~1362.
[9] Yu Zuyuan, Masuzawa, Takahisa, Fujino M. 3D micro-EDM with simple shape electrode. Part 1: Machining of cavities with sharp corners and electrode wear compensation. International Journal of Electrical Machining, 1998(3) :7~12.
[10] Heath.P.J. Developments in applications of PCD tooling [J] .Journal of Materials Processing Technology 2001(11) :31~38.
[11] Philip Koshy, V.K. Jain, G.K. Lal. Grinding of cemented carbide with electrical spark assistance. Journal of Materials Processing Technology 1997(72):61~68.
[12] H. Juhr, H.-PSchulze, G. Wollenberg, K.Kunanza. Improved cemented carbide properties after wire-EDM by pulse shaping. Journal of Materials Processing Technology 2004(149): 178~183
[13] S.H. Lee, X.P. Li. Study of the effect of machining parameters on the machining characteristics in electrical discharge machining of tungsten carbide. Journal of Materials Processing Technology. 2001(115): 344~358.
[14]程学艳.超声波机床及其发展.新技术新工艺,2004(10):40~43.
[15]艾枫.一种新颖的超声振动加工技术.制造技术与机床,2007(3):25~27.
[16]郭钟宁等.难加工材料的超声电火花线切割复合加工工艺研究.电加工与具.2001(2):39~41.
[17]曹凤国,张勤俭.超硬材料的特种加工技术.新材料产业,2006(10):47~51.
[18]霍孟友,艾兴,张建华.超硬材料研究及展望.机械工艺师.1998(12):20~24.
[19]郭钟宁.超声线切割复合加工技术的研究实验.机械加工与自动化.2001(7):30~31.
[20]王贵成,张银喜.精密与特种加工.武汉理工大学出版社,2001.
[21]周曦亚,罗博.金属与超硬材料复合的研究.材料导报.2007(11):447~449.
[22]张勤俭,曹凤国,等.聚晶金刚石加工技术进展.金刚石与磨料磨具工程2006(4):76~80.
[23]冯彩梅,王为民,傅正义.可加工陶瓷材料及其制造技术的研究进展.武汉理工大学学报2004(5):35~37.
[24]康新龙.电火花复合加工原理及应用.机电产品开发与创新,2007(7):175~177.
[25]袁松梅,赵万生,等.超声电火花复合加工的研究进展.航空精密制造技术,1998(6):17~20.
[26]陈桂生.超声换能器设计.北京:海洋出版社,1984:10~81.
[27]袁易全.超声换能器.南京:南京大学出版社,1992:270~306.
[28]张云电.夹心式压电换能器及其应用.北京:科学出版设,2006(1) :59~79,103~107.
[29]曹白杨,董平,韩文仲,等.功率超声换能器应用与设计.华北航天工业学院学报,2000,10(2):24~27.
[30] L EMASTER R A,GRAFF K F.Influence of ceramic location on high power transducer performance.IEEE Ultrasonic Symposium Proceedings,1978:296~299.
[31] Eiji MORI.Ultrasonics International 89 Conference Proceedings:256.
[32] Kleesattel C.Uniform Stress Contours for Disk and Ring Resonators Bibrating in axially symmetric radial and torsional modes.Acustica,968,20:1~13.
[33] K W Klontz,D M Divan.Contactless power delivery system for mining applications.IEEE Trans. on Industry Applications,1995,31(1):27~35.
[34] Andrea Cardoni,Margaret Lucas.Enhanced vibration performance of ultrasonic block horns.Ultrasonics,2002,40:365~369.
[35] MOFFETT M B.Characterization of Terfenol-D for magnetost rictive transducers.J Acoust Soc Am,1991,89(3):1448~1455.
[36]林书玉.超声换能器的原理与设计.北京:科学出版社,2004:95~100,239~242.
[37]贺西平,程存弟.几种常见形状函数超声变幅杆性能参量的同意表达.陕西师范大学学报(自然科学版),1994(3):29~32.
[38]贺西平,高洁.超声变幅杆设计方法综述.声学技术,2006,25(1) :82~86.
[39] Yuji Watanabe.A study on a transducer-stepped type solid horn system for flexural mode ultrasonic high powertransducer with one dimensional construction.Ultrasonics International 91 Conference Proceedings,1991(34):435~438.
[40] Yuji Watanabe,Eiji Mori.A study on a new flexural-mode transducer-solid horn system and itsapplication to ultrasonic plastics welding.Ultrasonics,1996(34):235~238.
[41] Eiji MORI,Masami UNO.Analysis of torsional vibration of an ultrasonic exponential solid horn with a tool and its design considering fatigue limit.Bulletin of the Tokyo institute of technology,1963(51):63~80.
[42]苏达士等.超声加工与放电加工的几种复合加工方式.轻工机械.2004(3):75~77.
[43]袁松梅.小型超声电火花复合加工系统的研究,[博士学位论文].哈尔滨:哈尔滨工业大学,2000.11.
[44]徐明刚.超声振动-气体介质电火花复合加工技术及机理研究,[博士学位论文].山东:山东大学,2007.7.
[45]曹明让,杨世春,等.超声电火花复合加工速度工艺试验研究.新技术新工艺.2007(3):22~23.
[46] M.Komarala.超声加工表面粗糙度和精度的研究.国外金属加工.1990(1):1~6.
[47]郝建华,倪振文.超声加工工具材料硬度对其磨损影响的研究.电加工.1999(30):22~24.
[48]贾志新,张建华,艾兴.超声频间隙脉冲放电加工的放电特性和加工特性的理论研究.电加工,1994(6):25~28.
[49]竺志大,王占和,范仲俊.超声复合微细电火花加工机理与试验.新技术新工艺,2009(1):76~80.
[50]冯平法,郑书友,张京京.功率超声加工关键技术的研究进展.制造技术与机床,2009(5):57~62.