浏览全部资源
扫码关注微信
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
[ "冯 冲(1996-),男,山东德州人,硕士研究生,2019年于合肥工业大学获得学士学位,现就读于天津大学精密仪器与光电子学院,主要从事嵌入式系统开发,超声换能器的仿真及应用研究。E-mail: fchong_1996@163.com" ]
[ "宫 虎(1974-),男,安徽淮南人,副教授、博士生导师,主要从事超声加工、机器人集成制造、超精密加工和五轴加工等方面的研究。E-mail: gonghu@tju.edu.cn" ]
收稿日期:2022-02-18,
修回日期:2022-03-16,
纸质出版日期:2022-07-25
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.
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。
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.
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
0
浏览量
865
下载量
1
CSCD
关联资源
相关文章
相关作者
相关机构