电火花单脉冲放电实验研究

单脉冲放电过程是电火花放电加工的基础,借助脉冲个数和脉宽参数均可调的脉冲电源在不锈钢和紫铜两种材料的工件上进行了电火花单脉冲放电实验,对单脉冲放电蚀除的特征和规律进行了探索研究。对单脉冲放电蚀除凹坑尺寸的统计与分析结果表明:正极性加工得到的凹坑较大且形状规则,单脉冲能量较小时,凹坑直径深度比更大,能量利用率更低。     

单脉冲电火花加工电源的设计

单脉冲放电对电火花放电加工机理的研究具有重要的意义,通过对单脉冲放电凹坑的研究可以定性或是定量地分析蚀除率、表面粗糙度与电参数的关系.适合于课题研究目的的单脉冲放电电源是对单脉冲电火花加工机理深入分析的关键,详细地介绍了一种实验室单脉冲电源的制作方法.     

单晶硅放电蚀除机理研究及有限元分析

提出了单晶硅电火花加工蚀除机理假设,认为热应力在放电蚀除过程中起主要作用。建立了单晶硅电火花线切割放电模型,利用有限元法模拟了在单脉冲放电条件下单晶硅的温度场及热应力场分布。分别计算了单晶硅在温度场和热应力场作用下的蚀除量,并与实际放电切割蚀除量进行了对比,结果表明,实际蚀除量近似等于模拟得到的温度场与热应力场蚀除量之和,验证了对单晶硅电火花加工蚀除机理所作假设的正确性。     

电火花线切割温度场有限元分析及参数验证

建立了电火花线切割脉冲放电模型,利用有限元法分析了单脉冲放电的温度场分布。计算出该条件下工件及电极丝放电凹坑几何特征,与实际切割条件下的表面粗糙度、电极相对损耗比、切割速度等工艺指标进行了对比,并根据电火花线切割的加工特点进行了修正,研究了电火花线切割的蚀除规律。结果表明:模拟的单脉冲放电凹坑几何特征经修正后可以近似表征实际连续切割时的表面粗糙度;实际切割中放电点在电极丝上的通道转移是导致电极丝相对损耗较低的主要原因;考虑到实际切割相关因素,对理论切割速度进行修正后,其值与实际值是吻合的。     

气中电火花加工颗粒增强金属基复合材料的有限元分析

根据傅里叶热传导理论,建立了气中电火花放电加工颗粒增强金属基复合材料的二维有限元仿真模型。利用有限元软件ANSYS分别采用高斯热源模型和均匀热源模型对单脉冲放电加工金属基复合材料的温度场进行数值模拟。根据温度场的分布情况,对比分析了在两种不同热源模型下放电凹坑的形貌、直径和深度,并与实验结果进行比较,结果表明,与高斯热源模型相比,均匀热源模型能较好地预测单脉冲放电加工金属基复合材料的放电凹坑特征。根据电火花加工金属基复合材料的特点,对均匀热源模型中所采用的放电通道半径进行了修正,结果表明,修正后的模型能够比较准确地模拟单脉冲放电加工金属基复合材料放电凹坑的几何特征。     

电火花单脉冲放电加工的电热模型与实验研究

为了探索电火花放电加工过程中的材料去除机理,以均匀热源模型为基础,建立了单脉冲电火花加工铝合金6061的温度场的电热模型。利用ANSYS软件仿真获得了单脉冲放电产生的温度场,分析了熔融凹坑的直径、深度和体积随不同脉冲宽度的变化趋势。进行了电火花单脉冲放电加工实验,模拟计算结果和试验结果基本吻合,表明该电热模型可以比较准确地预测电火花单脉冲放电加工的温度场分布,为进一步预测电火花连续脉冲放电加工的温度场分布情况打下基础。     

电火花加工单脉冲放电通道直径扩展规律研究

电火花加工的加工表面是由一系列的脉冲放电凹坑叠加而成的,因此研究单脉冲放电通道直径的扩展规律,对研究电火花加工的工艺规律以及加工表面质量预测等具有非常重要的意义。研究脉冲放电通道的形成与扩展机理,讨论电压、极值电流、脉宽等放电参数对放电通道直径扩展的影响,并根据理论推导建立了单脉冲放电通道直径扩展的数学模型。以煤油作为电介质工作液开展了单脉冲放电试验,使用超景深显微镜对单脉冲放电凹坑的直径进行了测量,并把测量得到的单脉冲放电直径数据代入建立的数学模型进行回归求解。回归公式的计算值与试验测量得到的单脉冲直径数据吻合度较高。     

Cu/Cr复合电极电火花加工电蚀凹坑的数值仿真及实验分析

介绍了一种电火花加工的Cu/Cr复合电极,分析了影响电蚀凹坑的主要因素。以ANSYS温度场分布分析为基础,对复合电极的两部分Cu和Cr在单脉冲条件下的温度场进行了数值模拟,获得放电能量与电蚀凹坑尺寸之间的关系,并同实验进行了比较。结果表明,通过模拟温度场分布,能够较准确地得到电蚀凹坑的尺寸,为模拟连续放电过程提供了理论依据。     

半导体硅电极多通道放电机理研究

为了实现电火花加工同一时刻形成多个放电通道蚀除工件,克服现有放电加工理论中同一时刻仅有一个放电通道蚀除工件的限制,提出了采用半导体材料作为电极进行放电加工的新方法。首先,通过试验证明以半导体硅为电极加工金属可以形成多通道放电;其次,建立了半导体电极单通道放电等效电路模型,发现半导体电极在放电加工时不是一个等势体,并进行了电势差分布试验,验证了多通道放电形成的原因是远离放电点处的电势较高,可以同时形成击穿产生放电;最后,进行了半导体硅电极单脉冲放电试验及成型加工试验。试验结果显示,半导体硅电极通过1次脉冲放电同时形成多个放电通道,有效地分散放电能量,相较于金属电极,每个放电坑的直径和深度都显著减小。在相同放电参数下,对比钢电极,用硅电极进行电火花加工的表面粗糙度值下降71.7%。     

一种电火花加工单脉冲电源的研制

电火花加工过程可以认为是由连续的单个脉冲放电累加形成的结果。在电火花加工过程中,单个脉冲放电可以体现等离子体的精确性,通过研究单个脉冲的放电特点能方便分析放电蚀坑的特性,从而有利于利用单脉冲放电特点了解电火花加工过程,因此,研究单脉冲电源具有重要的作用。以AT90S8535单片机为核心芯片,完成用于电火花基础研究的独立式单脉冲电源的设计,主要介绍电源的主振控制电路、功率开关驱动电路以及检测电路的设计。在空气介质中进行单脉冲放电试验,获得了脉宽为5、50、180、400和800μs的放电电压波形,验证了脉冲电源设计的合理性。该脉冲电源可用于电火花单脉冲加工基础研究。     

Study on erosion mechanism of graphite electrode in two-electrode spark gap switch

In a high-powered single pulse system, the graphite electrode is better than other common metal electrodes for high energy transfer and pulse discharge. In this paper, the erosion mechanism of graphite electrode is investigated with the thermodynamics theory and the experimental results. Based on a simplified mathematical model, the graphite electrode erosion process of high-powered spark gap switch is also analyzed. The analysis results show that the relationship of the graphite electrode erosion and the charge transfer is linear, which is accordant with the experimental results.     

An analysis of surface erosion in electrical discharge machining

An analytical model for the computation of metal erosion by a single spark in electrical discharge machining is presented. The effect of plasma channel growth on metal removal was examined and good correlation was found between theoretical and experimental results. The model was further developed to study the effects of non-rectangular current pulse shapes on metal removal and relative electrode wear to establish the optimum current pulse form required to minimize relative electrode wear.     

微细电火花加工中电极材料的蚀除机理研究

在微细电火花加工过程中 ,由于放电时间极短 ,使得其阴阳两极的电极材料蚀除过程产生较大的差异。本文应用传热学和电场的基本理论 ,分别对微细电火花加工阴阳两极的材料蚀除机理进行了理论研究 ,得出了在窄脉宽微细电火花加工中 ,尽量缩短脉宽可提高阳极材料的去除效率 ,同时又不会明显增加阴极材料损耗的结论。为微细电火花加工脉冲电源设计及加工工艺的改进提供了理论依据     

Dimensional analysis of tool wear in electrical discharge machining

The erosion phenomenon was analysed by dimensional analysis. An empirical equation was obtained which relates the volume of material eroded from the tool electrode to the energy of the pulse, density, thermal conductivity, specific heat and latent heat of vaporization of the electrode material.     

Surface Nanostructuring of Steel in Electrospark Alloying with WC-Based Electrodes

The change in cathode mass and anode erosion during electrospark alloying is investigated, with different process kinetics. With increase in pulse length, the efficiency of deep electrospark alloying increases up to some limit determined by the electrode composition.     

Micro electrical discharge machining using high electric resistance electrodes

In micro electrical discharge machining (EDM), because the material removal per single pulse discharge mainly determines the minimum machinable size of a micro EDM, decreasing the material removal per single pulse discharge is important. In this study, in order to decrease the material removal per single pulse discharge, high electric resistance materials such as single-crystal silicon are used for electrodes. Analytical results show that when the electrode resistance increases, the peak value of the discharge current decreases, whereas the pulse duration increases. In addition, the discharge energy decreases when increasing the resistance. Silicon is used as a tool electrode, and the effect of resistivity of the silicon tool electrode on the diameter of discharge craters generated on the stainless steel workpiece is examined. Experimental results reveal that with increasing silicon electrode resistivity, the diameter of discharge craters decreases. Because the diameter of discharge craters can be decreased to 0.5 μm, improved finished surfaces of R_z 0.03 μm are obtained.     

混粉准干式电火花加工试验研究

提出一种混粉准干式电火花加工技术,其加工介质是气液固三相流混合物。试验结果表明,材料去除率与表面粗糙度随脉冲宽度、峰值电流及分层厚度的增大而增大,脉冲间隙作用则相反,提高空气压力既有助于提高材料去除率又可降低表面粗糙度,电极损耗随脉冲宽度增大而减小,当脉冲宽度较大时电极损耗接近于零,随峰值电流增大而增加。由于液滴、粉末的介入,气体介质的绝缘强度降低,放电间隙会增加,有利于电蚀产物的排除,可减少短路、电弧放电的发生率,加工稳定性得到提高,从而材料去除率得到提高;由于粉末会产生放电分散效果,电蚀凹坑深度减小,工件表面粗糙度降低。     

Reducing electrode wear ratio using cryogenic cooling during electrical discharge machining

In this study, cooling effect of copper electrode on the die-sinking of electrical discharge machining of titanium alloy (Ti-6Al-4V) has been carried out. Investigation on the effect of cooling on electrode wear and surface roughness of the workpiece has been carried out. Design of experiment plan for rotatable central composite design of second order with four variables at five levels each has been employed to carry out the investigation. Current intensity (I), pulse on-time (t _on), pulse off-time (t _off), and gap voltage (v) were considered as the machining parameters, while electrode wear and surface roughness are the responses. Analysis of the influence of cooling on the responses has been carried out and presented in this study. It was possible to reduce electrode wear ratio up to 27% by electrode cooling. Surface roughness was also reduced while machining with electrode cooling.