基于线框电极的电火花直孔套料加工研究

试验研究一种使用线框电极的电火花加工的新工艺———套料加工。根据正交试验原理设计了混合位级正交表来试验和分析粗加工时电加工参数对加工速度和电极损耗率的影响,以确定线框电极套料加工时最佳电规准参数。最后依据试验数据绘出了三维图形,更加直观地表达了试验的结果。     

弯曲孔电加工工艺的实验研究

实验研究探讨了一种使用线框电极的电火花套料加工的新工艺.根据正交试验方法来分析精加工时加工参数对加工速度、电极损耗和加工表面粗糙度的影响,以确定套料精加工时最佳的电规准参数.依据直孔套料加工参数在模具材料中加工出了圆弧弯曲孔.     

使用线框电极创成加工模具的曲面型腔

介绍了使用线框电极创成加工模具曲面型腔的工艺中所使用电极的形状和尺寸结构,对电极的进给路径、数控编程和粗加工的电规准作了简单说明,并列举了几个加工实例。     

模具的电火花套型加工工艺研究

使用紫铜丝制作线框电极，采用电火花腐蚀方法，以套型的方式加工模具型腔和型芯。分析了电火花套型加工的工艺原理、特点及加工工艺规律和加工效率。应用电火花套型加工工艺制作了模具型腔和型芯，并用该模具压制出了橡胶制品。电火花套型加工工艺的电极制作简单，可显著提高加工效率，降低生产成本。     

电火花加工TC4钛合金时电极损耗的探讨

从试验出发，在相同的条件下，用电火花成型加工方法加工钛合金TC4，分别使用紫铜和铜钨合金电极作对比试验研究。并对用不同电规准加工时的电极损耗机理和生产率（加工速度）作出了分析和探讨，得出了相应的结论。     

受压铜管钎焊对接

在制造风动冷冻机中,热交换器是主要设备之一。它是由108根ф10×1毫米紫铜管分九层左、右旋交替绕制而成。一般采用整盘铜管绕制,只焊接进、出口接头。面我厂只购进1.5～2米左右短铜管,必须焊接接长。例如第一层铜管为三根同时并排绕制,每根长22米左右。铜管绕制时,弯管外侧受拉应力,弯管内侧受压应力。其绕后工作压力为8公斤/厘米~2。试验压力为12公斤/厘米~2,保证不渗漏。这就给接头的焊     

电火花套料加工技术的实验探讨

通过使用管状空心电极采用套料的方法加工模具钢的实验研究，探索能优质高效地对模具材料进行加工的最佳工艺条件。实际生产中影响加工效果的因素很多，因此采用正交实验方法进行了实验分析，并对套料加工和实心电极的加工效率作了比较。     

微细电解加工实验研究

采用基于电化学腐蚀法制作直径80μm、长度3000μm的微细电极,分别使用微细圆柱电极和微细螺旋电极进行了加工实验,实验研究丧明微细螺旋电极在孔和槽的加工中比微细圆柱电极具有更快的加工速度以及更小的加工间隙.螺旋结构在加工中有助于排出加工间隙内电解产物,显著地提高了加工效率、加工精度及加工过程的稳定性.     

超声加工用厚电极换能器振子的频率方程研究

旋转超声加工是加工硬脆材料的一种较好方法。为实现长时间连续稳定工作,必须使用厚电极的超声换能器振子。目前,对厚电极换能器振子的研究较少,使用时一般采用近似计算与试验调整相结合的方法。为精确设计厚电极换能器振子,推导了单个厚电极换能器振子的频率方程,并使用模态试验分析和有限元仿真相结合的方法进行了验证,结果表明:在给定的电极厚度范围内,换能器振子的谐振频率误差小于5％,完全满足工程应用的需要。     

弯曲孔加工技术及新方法

简析弯曲孔加工中的一些关键技术,介绍几种弯曲孔加工方法及其特点,着重说明基于线框电极的弯曲孔加工新工艺的原理、装置、影响因素和加工结果。     

模具型腔三维曲面的电火花套型加工

简单介绍了电火花套型加工的基本规律,分析了采用复杂形状电极套型加工复杂型腔的特性和困难,着重阐述了采用简单形状电极套型加工三维曲面模具型腔的工艺方法,包括电极制作,加工路径选定,程序编写及加工轨迹的简单仿真。最后展示了用这种工艺所加工的模具型腔和型芯。     

电火花加工多材质电极制备方法及试验研究

随着电火花加工技术的不断发展,利用多材质电极来实现微小复杂曲面的电火花成形加工,具有加工速度快、一次成形等特点而被广泛应用.针对多材质电极的制备,以黄铜、紫铜、铁、钼及铜钨合金等材质电极在模具钢上进行了加工试验,以研究的电极损耗及形状变化规律为基础,根据复杂曲面加工需求设计多材质电极,运用热镀法制备多材质电极,通过扫描...     

涡轮叶片冷却孔电火花加工管电极的铜电铸层制备及其抗电蚀性

以降低高温镍基合金涡轮叶片冷却孔电火花加工电极损耗率为目标,基于精密电铸工艺,优化了铸液工艺参数,在添加纳米La₂O₃条件下制备了铜管电极的铜电铸层,并将其与未添加La₂O₃所制备的铜电铸层进行了材料性能对比分析。以Inconel 718镍基合金叶片冷却孔为加工对象,利用所制备的带有纯铜电铸层的管电极进行了抗电蚀性能对比研究。试验结果表明：铸液中La₂O₃的添加量为1.2g/L时,铜电铸层晶粒最细,晶粒平均直径为15.9μm,表面粗糙度降至0.140μm,显微硬度可达98.2HV;用其制成的铜管电极损耗率较普通紫铜管电极和未添加纳米La₂O₃的铜管电极损耗率分别降低了13.29%和7.26%。     

Soft computing models based prediction of cutting speed and surface roughness in wire electro-discharge machining of tungsten carbide cobalt composite

This paper reports on an experimental investigation of small deep hole drilling of Inconel 718 using the EDM process. The parameters such as peak current, pulse on-time, duty factor and electrode speed were chosen to study the machining characteristics. An electrolytic copper tube of 3 mm diameter was selected as a tool electrode. The experiments were planned using central composite design (CCD) procedure. The output responses measured were material removal rate (MRR) and depth averaged surface roughness (DASR). Mathematical models were derived for the above responses using response surface methodology (RSM). The results revealed that MRR is more influenced by peak current, duty factor and electrode rotation, whereas DASR is strongly influenced by peak current and pulse on-time. Finally, the parameters were optimized for maximum MRR with the desired surface roughness value using desirability function approach.     

钛合金深小孔超声电火花加工工艺与实验研究

针对钛合金深小孔加工的技术难点,研制了具有四轴联动功能的微细超声电火花加工机床,在所研制的机床上,进行了钛合金深小孔超声电火花复合加工实验,就超声振动及削边电极在加工中的作用进行了系统和研究。     

The Potential of Plating Techniques in the Development of Rapid EDM Tooling

Electrodischarge machining (EDM) is a widely used process in the manufacturing of mould cavities for plastic products. EDM work typically accounts for a large portion of overall production time. A major cost and time element of EDM is electrode production, which can account for more than 50% of the total machining costs. A large complex electrode profile, which is very difficult to produce through machining and is also time consuming, can be easily produced using the rapid prototyping (RP) technique. The direct laser sintering of metal powders is a widely established RP process that can be employed for the rapid production of EDM electrodes. In this study, the above-mentioned technique has been employed. The powder mixture used in this process consists of copper, tin, nickel and phosphorus. An infra-red (IR) 200 W CO2 laser is used to sinter the powdered metals layer-by-layer in order to form solid electrodes. Electroless copper and copper plating are then employed to improve the surface finishing and the conductivity of the sintered electrode as it deposits a uniform thickness of metal onto the substrate by chemical reaction, without building up at the edges and corners, and achieves unique physical characteristics. The performance of the newly developed electrode is very similar to that of conventional copper electrodes. It is found that integration of RP and electroless plating techniques can be a potential means of the rapid production of EDM electrodes at low cost.     

Micro-hole Maching of Copper Using the Electro-discharge Machining Process with a Tungsten Carbide Electrode Compared with a Copper Electrode

This paper describes micro-hole machining of a copper plate using the electro-discharge machining (EDM) process. Tungsten carbide was selected as the material for the electrode and compared with a copper-electrode. A precision centreless grinding process was employed to grind the electrode down to the desired diameter. A series of experiments were performed on a traditional EDM machine to investigate the effects of electrode material polarity setting and of a rotating electrode. Results have shown that electrode wear and hole enlargement are both smaller when positive polarity machining is selected; whereas electrode wear is larger and machining speed is higher when negative polarity machining is selected. High-quality micro-hole machining in copper can be achieved by the proposed method.