Design and experiment of ultrasonic vibration composite EDM small hole drilling system

Chong FENG; Hao NI; Yijia SUN; Shuyu GUI; Hu GONG

doi:10.37188/OPE.20223014.1694

您当前的位置：

首页 >

文章列表页 >

Design and experiment of ultrasonic vibration composite EDM small hole drilling system

Micro/Nano Technology and Fine Mechanics | 更新时间：2022-08-08

- Design and experiment of ultrasonic vibration composite EDM small hole drilling system
- Optics and Precision Engineering Vol. 30, Issue 14, Pages: 1694-1703(2022)
- 作者机构：
  
  1.天津大学精密仪器与光电子工程学院精密测试技术及仪器国家重点实验室，天津 300072
  2.天津城建大学理学院，天津 300384
- 作者简介：
- 基金信息：
- DOI：10.37188/OPE.20223014.1694
  CLC： TH162
- Received：18 February 2022，
  
  Revised：16 March 2022，
  
  Published：25 July 2022
- 稿件说明：
移动端阅览
冯冲,倪皓,孙艺嘉等.超声振动复合电火花小孔加工系统设计及试验[J].光学精密工程,2022,30(14):1694-1703.

FENG Chong,NI Hao,SUN Yijia,et al.Design and experiment of ultrasonic vibration composite EDM small hole drilling system[J].Optics and Precision Engineering,2022,30(14):1694-1703.
冯冲,倪皓,孙艺嘉等.超声振动复合电火花小孔加工系统设计及试验[J].光学精密工程,2022,30(14):1694-1703. DOI： 10.37188/OPE.20223014.1694.

FENG Chong,NI Hao,SUN Yijia,et al.Design and experiment of ultrasonic vibration composite EDM small hole drilling system[J].Optics and Precision Engineering,2022,30(14):1694-1703. DOI： 10.37188/OPE.20223014.1694.

摘要

针对难加工的镍基高温合金小孔加工，设计了一种新颖的超声振动复合电火花小孔高速加工系统，该系统集成了电极超声振动、电极旋转和电极中心出水等功能，可方便地应用于其他电火花加工机床，并在镍基高温合金GH4099材料工件上开展了一系列小孔加工试验。通过改变加工电流和时间，对比材料去除率、电极损耗率和小孔形貌等指标。试验结果表明：超声振动复合加工在小电流加工时，可以有效地提升材料去除率，并减少相对电极损耗率。在同等条件下，当峰值电流为1 A时，使用该系统加工的孔深度较普通电火花加工的提升89.62%；当峰值电流为6 A时，相比于普通电火花加工材料去除率提升46.42%，相对电极损耗率减少了25.85%。该系统具有更稳定的加工过程，为难加工金属电火花精加工提供一种便利、高效的解决方案。

Abstract

A novel ultrasonic-vibration-composite electrical-discharge-machining （EDM） small-hole high-speed machining system is designed for small-hole machining of difficult-to-machine metals， such as nickel-based superalloys. The system can simultaneously realize the functions of electrode ultrasonic vibration， electrode rotation， and water flush out at the center of the electrode. It can be easily employed for other EDM machines. A series of small-hole machining experiments are carried out on the superalloy GH4099. By altering the machining current and time， indexes such as the material removal rate （MRR）， tool electrode wear rate （TWR）， and hole morphology are compared. The experimental results reveal that ultrasonic-vibration-composite machining can effectively improve the MRR and reduce the relative TWR during low-current machining. Under the same conditions， when the peak current is 1 A， the hole depth processed by this system is 89.62% higher than that of ordinary EDM. When the peak current is 6 A， the MRR increases by 46.42% compared with that for ordinary EDM. The electrode wear rate is reduced by 25.85%. Thus， we can conclude that the proposed system features a notably stable machining process that provides a convenient and efficient solution for EDM finishing of difficult-to-machine metals.

关键词

Keywords

references

SUN J F ， HUANG S ， DING H T ， et al . Cutting performance and wear mechanism of Sialon ceramic tools in high speed face milling GH4099 ［J］. Ceramics International ， 2020 ， 46 （ 2 ）： 1621 - 1630 . doi: 10.1016/j.ceramint.2019.09.134 http://dx.doi.org/10.1016/j.ceramint.2019.09.134

朱涛，张建华，常伟杰，等 . 超声振动辅助电火花铣削间隙流场分析与验证［J］. 中国机械工程， 2012 ， 23 （ 14 ）： 1712 - 1717 . doi: 10.3969/j.issn.1004-132X.2012.14.019 http://dx.doi.org/10.3969/j.issn.1004-132X.2012.14.019

ZHU T ， ZHANG J H ， CHANG W J ， et al . Theoretical analysis and verification for flow field of ultrasonic vibration aided electro-discharge milling ［J］. China Mechanical Engineering ， 2012 ， 23 （ 14 ）： 1712 - 1717 . （in Chinese） . doi: 10.3969/j.issn.1004-132X.2012.14.019 http://dx.doi.org/10.3969/j.issn.1004-132X.2012.14.019

NI H ， GONG H ， DONG Y H ， et al . A comparative investigation on hybrid EDM for drilling small deep holes ［J］. The International Journal of Advanced Manufacturing Technology ， 2018 ， 95 （ 1/2/3/4 ）： 1465 - 1472 . doi: 10.1007/s00170-017-1282-1 http://dx.doi.org/10.1007/s00170-017-1282-1

WONG Y S ， LIM L C ， LEE L C . Effects of flushing on electro-discharge machined surfaces ［J］. Journal of Materials Processing Technology ， 1995 ， 48 （ 1/2/3/4 ）： 299 - 305 . doi: 10.1016/0924-0136(94)01662-k http://dx.doi.org/10.1016/0924-0136(94)01662-k

WANG Y Q ， CAO M R ， YANG S Q ， et al . Numerical simulation of liquid-solid two-phase flow field in discharge gap of high-speed small hole EDM drilling ［J］. Advanced Materials Research ， 2008 ， 53/54 ： 409 - 414 . doi: 10.4028/www.scientific.net/amr.53-54.409 http://dx.doi.org/10.4028/www.scientific.net/amr.53-54.409

TANJILUL M ， AHMED A ， KUMAR A S ， et al . A study on EDM debris particle size and flushing mechanism for efficient debris removal in EDM-drilling of Inconel 718 ［J］. Journal of Materials Processing Technology ， 2018 ， 255 ： 263 - 274 . doi: 10.1016/j.jmatprotec.2017.12.016 http://dx.doi.org/10.1016/j.jmatprotec.2017.12.016

ZHANG Y ， XU Z Y ， ZHU Y ， et al . Effect of tube-electrode inner structure on machining performance in tube-electrode high-speed electrochemical discharge drilling ［J］. Journal of Materials Processing Technology ， 2016 ， 231 ： 38 - 49 . doi: 10.1016/j.jmatprotec.2015.12.012 http://dx.doi.org/10.1016/j.jmatprotec.2015.12.012

贾振元，任小涛，刘巍，等 . 大深径比微小孔快速电火花加工系统［J］. 光学精密工程， 2009 ， 17 （ 12 ）： 3055 - 3061 . doi: 10.3321/j.issn:1004-924X.2009.12.027 http://dx.doi.org/10.3321/j.issn:1004-924X.2009.12.027

JIA Z Y ， REN X T ， LIU W ， et al . Rapid EDM systems for micro and small holes with high-aspect-ratio ［J］. Opt. Precision Eng. ， 2009 ， 17 （ 12 ）： 3055 - 3061 . （in Chinese） . doi: 10.3321/j.issn:1004-924X.2009.12.027 http://dx.doi.org/10.3321/j.issn:1004-924X.2009.12.027

LI Z K ， TANG J J ， BAI J C . A novel micro-EDM method to improve microhole machining performances using ultrasonic circular vibration （UCV） electrode ［J］. International Journal of Mechanical Sciences ， 2020 ， 175 ： 105574 . doi: 10.1016/j.ijmecsci.2020.105574 http://dx.doi.org/10.1016/j.ijmecsci.2020.105574

KREMER D ， LHIAUBET C ， MOISAN A . A study of the effect of synchronizing ultrasonic vibrations with pulses in EDM ［J］. CIRP Annals ， 1991 ， 40 （ 1 ）： 211 - 214 . doi: 10.1016/s0007-8506(07)61970-2 http://dx.doi.org/10.1016/s0007-8506(07)61970-2

LI G D ， NATSU W ， YU Z Y . Elucidation of the mechanism of the deteriorating interelectrode environment in micro EDM drilling ［J］. International Journal of Machine Tools and Manufacture ， 2021 ， 167 ： 103747 . doi: 10.1016/j.ijmachtools.2021.103747 http://dx.doi.org/10.1016/j.ijmachtools.2021.103747

PRIHANDANA G S ， MAHARDIKA M ， HAMDI M ， et al . Effect of micro-powder suspension and ultrasonic vibration of dielectric fluid in micro-EDM processes-Taguchi approach ［J］. International Journal of Machine Tools and Manufacture ， 2009 ， 49 （ 12/13 ）： 1035 - 1041 . doi: 10.1016/j.ijmachtools.2009.06.014 http://dx.doi.org/10.1016/j.ijmachtools.2009.06.014

SHABGARD M R ， ALENABI H . Ultrasonic assisted electrical discharge machining of Ti-6Al-4V alloy ［J］. Materials and Manufacturing Processes ， 2015 ， 30 （ 8 ）： 991 - 1000 . doi: 10.1080/10426914.2015.1004686 http://dx.doi.org/10.1080/10426914.2015.1004686

LIAO Y S ， LIANG H W . Study of vibration assisted inclined feed micro-EDM drilling ［J］. Procedia CIRP ， 2016 ， 42 ： 552 - 556 . doi: 10.1016/j.procir.2016.02.250 http://dx.doi.org/10.1016/j.procir.2016.02.250

GOIOGANA M ， SARASUA J A ， RAMOS J M ， et al . Pulsed ultrasonic assisted electrical discharge machining for finishing operations ［J］. International Journal of Machine Tools and Manufacture ， 2016 ， 109 ： 87 - 93 . doi: 10.1016/j.ijmachtools.2016.07.005 http://dx.doi.org/10.1016/j.ijmachtools.2016.07.005

BELLOTTI M ， QIAN J ， REYNAERTS D . Breakthrough phenomena in drilling micro holes by EDM ［J］. International Journal of Machine Tools and Manufacture ， 2019 ， 146 ： 103436 . doi: 10.1016/j.ijmachtools.2019.103436 http://dx.doi.org/10.1016/j.ijmachtools.2019.103436

郑新毅，贾振元，任小涛，等 . 用正交试验分析电参数对小孔圆柱度的影响［J］. 光学精密工程， 2010 ， 18 （ 2 ）： 426 - 433 .

ZHENG X Y ， JIA Z Y ， REN X T ， et al . Analysis on effect of discharge parameters on cylindricity of small holes by orthogonal experiments ［J］. Opt. Precision Eng. ， 2010 ， 18 （ 2 ）： 426 - 433 . （in Chinese）

PHAM D T ， IVANOV A ， BIGOT S ， et al . An investigation of tube and rod electrode wear in micro EDM drilling ［J］. The International Journal of Advanced Manufacturing Technology ， 2007 ， 33 （ 1/2 ）： 103 - 109 . doi: 10.1007/s00170-006-0639-7 http://dx.doi.org/10.1007/s00170-006-0639-7

Views

930

下载量

CSCD

Alert me when the article has been cited

提交

Tools

Publicity Resources

Design of ultrasonic magnetorheological finishing excitation device for medical bone screw

Analysis of electrical parameters effect on cylindricity in electrical discharge machining small hole

An experimental study in small-holes EDM by current dividing

Design of micromanipulation instrument for bio-microdissection

Experimental Investigation of the Ultrasonic Vibration Abrasive Tape Polishing

Related Author

Axiang JI

Hongyun WANG

Cheng BI

Aiqun XU

郑新毅

贾振元

任小涛

王福吉

Related Institution

College of Mechanical and Energy Engineering， Zhejiang University of Science and Technology

School of Aeronautical Engineering， Taizhou University

大连理工大学机械工程学院2. 大连理工大学

大连理工大学

Robotic Institute, Harbin Institute of Technology, Harbin 150001,China

AI问答

Address：No.3888 Dong Nanhu Road, Changchun, Jilin, China Postal code：130033
Tel：0431-86176855 Email：gxjmgc@ciomp.ac.cn
Technical support is provided by Beijing Founder electronics co., LTD 吉ICP备11002662号-17 京公网安备11010802024621
It is recommended to read the content of this site in Chrome&IE9+. Please switch to extreme mode in browser 360.
Cookies We use cookies to help provide and enhance our service and tailor content. By continuing, you agree to the use of cookies.

⁰