脉冲电解和直流电解磨削加工的对比实验和研究

通过脉冲电解和直流电解磨削加工的工艺对比实验，其分析结果表明，脉冲电解磨削加工的工件尺寸精度高，表面质量好，同时还得到了电解参数对工件尺寸精度和表面粗糙度值的影响规律。选择脉冲电解磨削的电参数非常重要，其中电流密度有一个相对最佳的选择值。     

超声振动辅助电解加工成形规律研究及试验

超声振动辅助电解加工可以有效提高加工效率、改善加工精度。对超声振动辅助电解加工成形过程进行了分析,研究其加工成形机理,并根据加工成形质量对加工参数进行优选。设计了3种不同截面形状的柱状阴极工具进行超声振动辅助电解加工微孔的试验研究,分析了极间脉冲电压、占空比和振动加工方式等参数条件对加工效率、表面质量及微结构入口尺寸的影响规律。试验结果表明,超声振动改善了电解加工时的微孔边界成形作用环境,在加工阵列微孔时具有显著优势。当超声振动同步辅助电解加工的高频脉冲电压为4 V、占空比为40%时,加工深度、关键尺寸和表面粗糙度值达到了综合最优值。此外,加工工具的截面形状对工件的成形和表面质量也有一定的影响。     

硬质合金的电解磨削镜面加工试验

电解磨削加工优于机械研磨、电解抛光和电解磨料复合加工，适用于内外国磨削、平面磨削、成形磨削。尤其对硬质含金、高速钢、不锈钢、钛合金、镍合金、纯铁等高强度、高硬度、热敏性和磁性等难加工材料的工件表面，可将粗磨、精磨、镜面加工连续进行，将加工前粗糙度为Ra63～1．6μm的工件表面直接电解磨削至Rao.025Pm以下的镜面。本文介绍硬质含金的电解磨削镜面加工试验。一、试验实例1．试件材料、尺寸及初始粗糙度试件材料为国产YT15硬质合金，被磨平面尺寸为20×60（mm2）（厚10．5mm），初始表面粗糙度为Ra1．6μm。2磨床、磨轮及…     

光学玻璃超精密镜面磨削表面质量影响试验研究

在线电解砂轮修整(ELID)磨削技术是一项新的、高效的磨削方法,可用于许多难加工材料的超精密加工和高效加工。采用ELID磨削方法对光学玻璃进行精密加工,通过实验研究了ELID磨削中电解电流和电压对加工表面的影响,得到了一定条件下优化的电解频率、电解电压参数。结果表明:在较高的电解频率下,加工工件的表面质量较好,但电解频率过高,表面质量会出现下降;加工工件的表面质量随着电解电压的增大有降低的趋势;在本文试验条件下,电解频率为100kHz,电解电压为60V时,加工表面质量最好。     

MEEC加工新方法

由日本某研究所开发研制的MEEC加工法是由机械磨削、电解加工和电火花加工三种方法所组成的。它能最大限度地有效利用各自的加工方法的特性及其优点。如图1所示,在具有特殊结构的导电砂轮(MEEC磨轮)和工件上施加电压,并注入电解电火花磨削液(MEEC加工液),当砂轮高迅旋转时,就会不断发生脉冲放电,对工件进行电解加工,这样增加了机械磨削功能。其具体过程是:当MEEC磨轮     

MEEC加工新方法

<正> 由日本某研究所开发研制的MEEC加工法是由机械磨削、电解加工和电火花加工三种方法所组成的。它能最大限度地有效利用各自的加工方法的特性及其优点。如图1所示,在具有特殊结构的导电砂轮(MEEC磨轮)和工件上施加电压,并注入电解电火花磨削液(MEEC加工液),当砂轮高迅旋转时,就会不断发生脉冲放电,对工件进行电解加工,这样增加了机械磨削功能。其具体过程是:当MEEC磨轮     

提高电解成型磨削精度的有效方法

在电解磨削过程中,为获得理想的生产率和加工精度,除了根据被加工工件要求,合理地选择电解液、导电磨轮和电流密度、加工电压、磨削压力、进给速度及磨轮线速度等主要工艺参数外,另一个重要因素就是电解液的供给方式和供给量。     

ELID精密镜面磨削系统电源的使用分析

分析了在线电解磨削(ELID)精密镜面磨削系统的不同电源,通过实验,详细阐述直流电源和直流脉冲电源的电解特点.通过参数对比,得出两种不同电源各自的使用范围,对ELID精密镜面加工电源的选择有较好的指导作用.     

超短脉冲电流微细电解加工技术研究

利用电化学腐蚀方法,在自制的电解加工机床上连续实现微细工具电极的制作和工件的加工,通过试验研究了超短脉冲的电压幅值和脉冲宽度对侧面加工间隙的影响。结果表明,减小脉冲宽度,降低加工电压,可以提高微细电解加工的精度。利用优化的加工参数,进行了微小孔加工、微细直写加工以及成形电极微细加工的实验。     

非导电工程陶瓷电火花磨削技术

开发出双电极同步伺服跟踪电火花磨削新技术,该技术突破了传统的机械磨削和电解电火花机械复合磨削方法,利用导电磨轮与紧贴非导电工程陶瓷工件表面作自动伺服进给运动的薄片辅助电极间的放电实现电火花磨削。对非导电的Al2O3工程陶瓷进行加工试验,给出加工参数如脉冲宽度、脉冲间隔、峰值电压、峰值电流、磨轮转速以及铜片电极厚度等对材料去除率和表面粗糙度的影响规律关系。试验结果表明,该种新型加工技术具有效率高、表面质量好、成本低和对环境无污染等优点。     

微槽激光电解组合微加工研究

微槽结构作为微型结构的基本单元,具有增加散热面积、存储润滑剂和减少阻力等功能,多用于大热流密度器件的散热或表面润滑,但其存在加工尺寸小、精度要求高以及加工难度大等问题.为了实现微槽的高效高精度加工,提出了一种激光电解组合微加工方法,并搭建了纳秒激光加工装置和数控微细电解加工装置;利用激光烧蚀快速加工出微槽结构的基本形貌...     

Detection of the eroding surface in the EDM process based on the current signal in the gap

To achieve a high removal rate and low electrode wear in a sinking electrical discharge machining process (EDM), rough machining parameters have to be selected according to the size of the eroding surface. In general, the size of the eroding surface varies according to the depth of the machining. Thus, it has to be determined on-line. This paper shows that the electric current signal in the gap depends on the size of the eroding surface. The significance of the process attributes of the electric current signal is established by inductive machine learning and the general decision rules are derived. The size of the eroding surface can be detected on-line by monitoring and evaluating the electric current signal in the gap.     

Detection of the eroding surface in the EDM process based on the current signal in the gap

To achieve high removal rate and low electrode wear in sinking electrical discharge machining process (EDM), rough machining parameters have to be selected according to the size of the eroding surface. In general, the size of the eroding surface varies according to the depth of the machining. Thus, it has to be determined on-line. This paper shows that the electric current signal in the gap depends on the size of the eroding surface. The significance of the process attributes of the electric current signal is established by inductive machine learning and the general decision rules are derived. The size of the eroding surface can be detected on-line by monitoring and evaluating the electric current signal in the gap.     

Finishing effect of abrasive flow machining on micro slit fabricated by wire-EDM

This experimental research use the method of abrasive flow machining (AFM) to evaluate the characteristics of various levels of roughness and finishing of the complex shaped micro slits fabricated by wire electrical discharge machining (Wire-EDM). An investigative methodology based on the Taguchi experimental method for the micro slits of biomedicine was developed to determine the parameters of AFM, including abrasive particle size, concentration, extrusion pressure and machining time. The parameters that influenced the machining quality of the micro slits were also analyzed. Furthermore, in the shape precision of the micro slit fabricated by wire-EDM and subsequently fine-finished by AFM was also elucidated using a scanning electron microscope (SEM). The significant machining parameters and the optimal combinations of the machining parameters were identified by ANOVA (analysis of variation) and the S/N (-to-noise) ratio response graph. ANOVA was proposed to obtain the surface finishing and the shape precision in this study.     

高回转精度多阶柱状微电极电化学高效制备试验研究

为实现高回转精度多阶柱状微电极的高效加工,对多阶柱状电极电化学刻蚀过程进行了深入的研究与改进。首先,根据电化学刻蚀理论推导了加工电流对电极直径变化的影响规律;通过试验证明了电极旋转可提高电流变化速率及有效起始电流进而提高加工效率,定性分析了电极旋转对电极回转精度的影响,提出了分阶变转速高效加工高回转精度多阶柱状微电极的方法;通过试验分析了各加工参数(电极转速、加工电压和切断电流)对电极形状及尺寸的影响;最后,在优化后的加工参数下,成功加工得到末端直径小于15μm且同轴度误差在1μm以内的多阶柱状微电极,与常规电化学刻蚀工艺相比,显著提高了加工效率。试验证明旋转电化学刻蚀是一种能够较好地提高微电极加工效率及回转精度的新工艺。     

火箭发动机涡轮泵高速齿轮的制造

火箭发动机涡轮泵高速齿轮,要求可靠性高。涡轮泵齿轮的制造工艺必须使齿轮具有高的强度和韧性,无潜在缺陷、因加工引起的内应力低、加工表面质量好、尺寸与形状精度高等特性。涡轮泵齿轮制造的最重要工序为精磨齿。文中对磨齿的工艺基准、磨齿裕量、磨齿用量和防止齿面烧伤等问题做了分析,并提出了相应的最佳结果。     

Electrical discharge precision machining parameters optimization investigation on S-03 special stainless steel

S-03 is a novel special stainless steel, which is widely used in precision aerospace parts and electrical discharge machining technology has the merit of high-accuracy machining. This paper aims to combine gray relational analysis and orthogonal experimental to optimize electrical discharge high-accuracy machining parameters. The four process parameters of gap voltage, peak discharge current, pulse width, and pulse interval are required to optimize in the fewest experiment times. The material removal rate and surface roughness are the objective parameters. The experiment were carried out based on Taguchi L9 orthogonal array, then we carried out the gray relational analysis to optimize the multi-objective machining parameter, finally, we verified the results through a confirmation experiment. The sequence of machining parameters from primary to secondary are as follows: discharge current 7A, pulse interval 100 μs, pulse width 50 μs, and gap voltage 70 V. Using the above machining parameters, we can obtain good surface roughness Ra1.7 μm, and material removal rate 13.3 mm³/min. The machined work piece almost has no surface modification layer. The results show that combining orthogonal experiment and gray relational analysis can further optimize machining parameters, the material removal rate increased by 23.8 %, and the surface roughness almost has no change.     

钛合金精密零件镗铣加工工艺

对钛合金精密零件加工工艺技术的研究,通过选用适合加工钛合金材料的刀具、切削要素,提高钛合金精密零件加工质量,通过制定合理的热处理参数及工艺流程消除零件加工应力,稳定零件加工尺寸,选用合适的定位方式消除零件的加工过定位,保证零件加工尺寸精度,试验表明此工艺加工方法可消除零件加工变形,稳定加工尺寸,使钛合金精密零件合格率达到95%以上,从而达到保证零件尺寸精度的技术要求。     

复杂曲面高效铣削加工的刀具尺寸优选

刀具尺寸是影响复杂曲面数控加工质量和效率的重要因素,基于刀具尺寸与曲面加工质量和效率的函数关系,给出了保证加工曲面精确性的最优小刀具选择方法,建立了以效率最高为目标的合理大刀具尺寸优选算法,并针对几何特征复杂的曲面,提出了以刀具加工有效面积比值为参考的刀具组合选择方法。应用实例表明:该刀具尺寸优选策略在充分保证复杂曲面加工质量的前提下,能有效提高其整体加工效率。     

Optimization of wire electrical discharge machining (WEDM) process parameters using Taguchi method

Wire electrical discharge machining (WEDM) is extensively used in machining of conductive materials when precision is of prime importance. Rough cutting operation in WEDM is treated as a challenging one because improvement of more than one machining performance measures viz. metal removal rate (MRR), surface finish (SF) and cutting width (kerf) are sought to obtain a precision work. Using Taguchi’s parameter design, significant machining parameters affecting the performance measures are identified as discharge current, pulse duration, pulse frequency, wire speed, wire tension, and dielectric flow. It has been observed that a combination of factors for optimization of each performance measure is different. In this study, the relationship between control factors and responses like MRR, SF and kerf are established by means of nonlinear regression analysis, resulting in a valid mathematical model. Finally, genetic algorithm, a popular evolutionary approach, is employed to optimize the wire electrical discharge machining process with multiple objectives. The study demonstrates that the WEDM process parameters can be adjusted to achieve better metal removal rate, surface finish and cutting width simultaneously.