浅析电参数对快走丝电火花线切割表面质量和加工精度的影响

针对快走丝电火花线切割中存在的表面质量差、加工精度低的问题,分析了快走丝电火花线切割加工条件中放电参数（脉冲宽度ON、功率管数IP、脉冲间隔OFF、开路电压、脉冲频率）对零件表面粗糙度、加工精度的影响,为快走丝电火花线切割加工积累了经验。     

电火花加工SiCp/Al复合材料微细孔的技术研究

使用μ-spark2000机床对SiCp/Al复合材料进行电火花加工微细孔的工艺实验,分析了开路电压、电容、电极材料与加工速度和电极损耗之间的关系,总结了开路电压和电容对加工精度和表面粗糙度的影响规律,并成功加工出φ53 μm的微细阵列孔.     

电火花加工SiCp／AI复合材料微细孔的技术研究

使用μ-spark2000机床对SiCp／AI复合材料进行电火花加工微细孔的工艺实验，分析了开路电压、电容、电极材料与加工速度和电极损耗之间的关系，总结了开路电压和电容对加工精度和表面粗糙度的影响规律，并成功加工出Ф53μm的微细阵列孔。     

钛铝金属间化合物电解线切割精整加工试验研究

提出了电火花线切割与电解线切割组合加工钛铝金属间化合物TiAl 45XD材料的方法,其中电解线切割精整加工一次“走刀”去除重铸层,二次“走刀”消除可能出现的晶间腐蚀。分别研究了铸造TiAl 45XD机械抛光表面和电火花线切割表面的电化学特性,发现两种表面在水基溶液中均有钝化现象,在乙二醇基溶液中几乎无明显的钝化现象,与在水基溶液中相比,两种表面在乙二醇基溶液中均更易被腐蚀,且电火花线切割表面较机械抛光表面的腐蚀程度更高。分析了进给速度和切深对表面完整性的影响,试验结果表明：一次“走刀”进给速度为25 μm/s、切深为20 μm,二次“走刀”进给速度为60 μm/s、切深为0时,重铸层被去除,无晶间腐蚀,表面粗糙度值减小至1.6 μm,平均进给速度为17.65 μm/s。该试验结果验证了使用电火花线切割粗成形、乙二醇基溶液电解线切割精整加工钛铝金属间化合物是可行的高表面完整性直纹构件加工方法。     

GH4169高温合金电火花线切割加工质量预测研究

针对镍-铬-铁基高温合金GH4169电火花线切割加工质量预测问题,通过正交实验设计并结合方差分析,分析放电电流及脉冲宽度、放电间隙、管数、加工限速对GH4169高温合金电火花线切割加工表面粗糙度和线切割速度的影响规律。在实验数据基础上训练BP神经网络,建立脉冲宽度、放电间隙、管数、加工限速对表面粗糙度和线切割速度影响的预测模型,预测结果表明,将正交实验与BP神经网络融合应用在GH4169高温合金电火花线切割加工中,不仅减少了工艺参数优化选择的盲目性,也提高了加工质量的预测精度和效率。     

快走丝线切割加工质量的影响因素与解决措施

表面粗糙度是衡量电火花线切割加工性能的重要指标之一.文中从主要影响电火花线切割加工表面粗糙度的机械因素、脉冲参数、进给速度、工作液性能等方面分析原因,并提出提高高速走丝线切割加工工件表面质量的方法.为提高高速走丝切割加工表面质量提供了参考.     

复杂回转体的电火花线切割加工及表面特性分析

论述了回转体电火花线切割的原理及应用,实验并分析了电火花脉冲宽度,线电极进给速度和工件旋转速度等加工参数对加工表面特性的影响,借助于扫描电子显微镜识别和量化了加工表面的重凝固层和热影响层。     

进给速度对高速走丝气中线切割加工的影响

研究了在大气和乳化液两种介质中，进给速度对高速走丝电火花线切割加工的影响。实验结果表明，气中加工的直线度好、放电间隙窄、加工速度(材料去除率)高。另外还发现，无论气中或液中加工时，进给速度都存在一个最佳的数值，使加工的粗糙度值呈现为最低值，同时加工速度值呈现为最高值。     

双工位分时互补电火花线切割加工工艺研究

针对常规电火花线切割同时加工多工件时出现放电不均匀,从而导致加工槽宽不一致的问题,提出了双工位分时互补电火花线切割加工的方法。该方法充分利用了脉间时间,采用多路脉冲分时互补供电加工方式,从而有效避免了加工过程中工件之间的互相干扰;在工艺试验中,采用了直径0.18 mm的钼丝作为工具线电极,厚度为8 mm的模具钢作为工件材料,探究了加工电压、运丝速度、电源频率、进给速度和脉间倍数对加工槽宽的影响规律,并对比分析了单路供电与分时互补供电方式下,双工位加工槽宽的一致性。研究结果表明:采用分时互补电火花线切割加工方法同时加工双工位工件的槽宽一致性更好;经试验优化,在加工电压为70 V、脉间倍数为5、进给速度20μm/s、电源频率14 kHz、运丝频率35 Hz时一致性最好。     

微细电火花线切割加工表面凸峰的高斯曲率

微细电火花线切割表面微观三维形貌与传统切削加工表面完全不同,属于各向同性表面,在对其进行三维粗糙度评定时,测量方向对混合参数的影响很大,测量方向选择不当,混合参数的计算精度很低,甚至出现计算结果与被测表面实际观测结果相反的情况。根据微细电火花线切割加工表面凸峰的特点,采用高斯曲率表征其表面凸峰的凹凸性,消除了测量方向对计算结果的影响。经试验验证,高斯曲率对微细电火花线切割加工表面凸峰的表征结果准确,计算精度高。     

纵-扭复合振动超声深滚加工工艺试验

采用正交试验法对Q235钢端面进行了纵-扭复合振动超声深滚加工,探索了工艺参数对表面粗糙度和显微硬度的影响,并基于试验结果构建了表面粗糙度和显微硬度的预测模型。试验结果表明：经纵-扭复合振动超声深滚加工后,工件表面粗糙度值显著减小,而显微硬度有大幅提高;表面粗糙度值随静压力增大先增后减,随进给量的增大而急剧增大,而随滚压速度的增大变化不明显,且进给量对表面粗糙度的影响最显著;显微硬度随静压力的增大而提高,随进给量和滚压速度的增大有微小波动,且静压力对显微硬度的影响最显著;基于t-检验与相关系数计算结果发现,进给量与静压力的交互作用对表面粗糙度的影响最大,而静压力与滚压速度的交互作用对显微硬度的影响最大。基于正交试验结果和预测模型获得了最优工艺参数,两者的结果接近,表明预测模型可靠。     

The parameters evaluation and optimization of polycrystalline diamond micro-electrodischarge machining assisted by electrode tool vibration

The objective of this research is to evaluate and optimize machining parameter of tool electrode vibration on micro-electric discharge machining of polycrystalline diamond. The machining parameters evaluated are charge voltage, capacitance, and vibration of the tool electrode. An orthogonal array, signal-to-noise ratio, and analysis of variance are employed to analyze the effect of these machining parameters. The results show that by application of vibration on tool electrode in machining of polycrystalline diamond, it has significant effect up to 66.48% in increasing material removal rate without increasing surface roughness and tool electrode wear. Using Taguchi method for design of experiment, other significant effects on surface quality and tool electrode wear are also investigated. The results also show that surface roughness is mostly affected by the amount of capacitance (52.24%), and the tool electrode wear is also affected by the amount of capacitance (92.82%).     

微磨料气射流成形加工表面粗糙度的研究

通过微磨料气射流成形加工玻璃试验,研究了工艺参数及其交互作用对加工表面粗糙度的影响,建立了表面粗糙度的回归模型。结果表明,气压对表面粗糙度的影响最显著,其次是靶距和喷嘴横移速度的交互作用、气压和靶距的交互作用以及靶距,而气压和喷嘴横移速度的交互作用、喷嘴横移速度对表面粗糙度的影响相对较小。表面粗糙度随着气压的增加而增大,随着靶距和喷嘴横移速度的增加先减小后增大。选用中低气压和较大靶距的组合有利于降低表面粗糙度。方差分析和残差检验的结果表明回归模型可以有效地预测表面粗糙度。     

高速铣削7050-T7451铝合金表面粗糙度研究

高速铣削广泛用于航空铝合金材料的加工,以7050-T7451铝合金材料为试验对象,运用正交试验方法分析研究了铣削该铝合金材料时,切削速度、切削深度、切削宽度和每齿进给量4个因素对表面粗糙度的影响规律,并通过多元非线性回归分析得出表面粗糙度的经验公式.研究结果表明:加工表面呈交叉织网状形貌,表面粗糙度随每齿进给量和铣削深度的增大而增大,随切削速度的增大而减小,切宽对铝合金表面粗糙度的影响不明显.铣削参数对表面粗糙度的影响显著性依次为:每齿进给量fz切削速度v轴向切削深度ap径向切削宽度ae.     

A parametric study of the 2D model of solar air heater with elliptical rib roughness using CFD

The heat transfer can be improved by providing artificial roughness on absorber plate of the solar air heat. Many studies are available on circular, semi-circular, triangular and rectangular rib roughened solar air heater. But in present study heat transfer enhancement by providing elliptical ribs on absorber plate was analyzed by developing CFD code on non-commercial ANSYS (Fluent) 12.1 software. The simulations were performed on 2-D CFD model and analysis was carried out to study the effect of relative roughness width, relative roughness height and relative roughness pitch on heat transfer and friction factor. The Reynolds number range from 4000 to 15000 and turbulence phenomena is modeled by using Reynolds-average Navier-Stokes equations (RANS). The mathematical modeling is validated and compared with available results. The strong vortex formation takes place in the main stream flow because of elliptical roughness, which improved heat transfer augmentation in the solar air heater. The local turbulence kinetic energy strongly influenced by orientation of the elliptical ribs. The value of average Nusselt number increases by increasing relative roughness height but it decreases with the increase of relative roughness width and relative roughness pitch. The rib width has significant effects on heat transfer enhancement and maximum Nusselt number is observed for relatively small roughness width (i.e., 0.5) among the considered range of 0.5 mm to 2.0 mm. The maximum value of Nusselt number and friction factor is observed for relative roughness width of 0.5, relative roughness height of 0.045, and relative roughness pitch of 6.

     

壁槽电极雾化烧蚀成形加工工艺

为解决放电雾化烧蚀成形加工盲型孔过程中出现的烧蚀颗粒大、排屑难、加工不稳定问题,制作了中空铜管与正方形紫铜块相结合的成形电极,分别对无壁槽电极和壁槽电极的极间流场及颗粒质量浓度分布进行了仿真分析与比较,基于极间流场仿真结果进行了雾化烧蚀对比实验,并对两种电极加工工件表面形貌进行了对比分析。实验结果表明：当槽宽为1 mm、倾斜角为60°时,烧蚀效率最高。在相同加工条件下进行雾化烧蚀加工时,与无壁槽电极相比,壁槽电极的蚀除速率提高了15.7%,壁槽电极的电极相对损耗率增大了6.2%。壁槽电极加工时的表面质量比无壁槽电极加工时的表面质量高。实验结果验证了仿真结果的正确性。     

正交磁场对电火花单脉冲放电间隙的影响

通过普通电火花单脉冲放电（EDM）与磁场辅助电火花单脉冲放电（MF-EDM）放电间隙对比试验,分析得出不同磁感应强度、开路电压、放电电容及电极外伸端长度对磁场辅助电火花加工放电间隙的影响规律。试验发现：随着磁感应强度的增大,放电间隙增大;开路电压和放电电容对放电间隙的影响较小;随着电极外伸长度的增大,放电间隙变小。最后对试验数据进行部分析因分析,得出磁场辅助电火花加工中影响放电间隙的主要因素为磁感应强度、电极外伸长度及其交互耦合作用。     

Fabricating microgrooves with varied cross-sections by electrodischarge machining

A two-step electrodischarge machining method was proposed for fabricating microgrooves with varied cross-sections on hard materials. Firstly, tungsten tool electrodes were shaped by wire electrodischarge grinding, and then the resulting tool electrodes were used to electrodischarge machine microgrooves on stainless steel. Preliminary experimental results showed that, in the first step, a sharp tool electrode with surface roughness of 0.3 µmRa could be achieved, and the surface roughness of the resulting groove was 0.16 µmRa in the second step. Voltage strongly affects the machining speed. A high voltage (>70 V) was preferable for improving the material removal rate. However, significant tool wear took place when using a high condenser capacitance at high voltages. To suppress tool wear, a high voltage and a small capacitance should be used. As test pieces, microgrooves having rectangular, triangular, circular and semi-closed cross-sections were fabricated.     

Effects of ball burnishing parameters on surface finish—A literature survey and discussion

Ball burnishing, a plastic deformation process, is becoming more popular as a finishing operation. A literature survey and discussion on the effects of the various types of burnishing (normal, vibratory and ultrasonic) and related parameters—force, speed, feed-rate, lubrication, ball material and diameter, workpiece material, pre-machined roughness and frequency of oscillation—on the final surface roughness are presented. The effect is an interaction between the process parameters with burnishing force and feed-rate as the two most significant factors. A particular surface finish can be obtained by appropriate selection of the parameters     

A Low Cost,High Resolution Interface Circuit for Differential Capacitance Transducer

Abstract

For accurately detecting capacitance changes of the differential‐capacitance transducer, which is widely used in environmental and chemical engineering, a low‐cost interface circuit was developed. The circuit uses a “lock‐in detection” circuit with feedback loop containing a DC amplifier and a modulator to yield such advantages over the others that it reduces the sensitivity to element parameter variations in the “lock‐in detection” circuit, that it decreases the sensitivity to the disturbances within closed‐loop, and that it is immune to parasitic capacitance, resistance, amplitude, and frequency of the excitation voltage source. The circuit has the capability to detect a capacitance change as small as 0.0078% of the total capacitance, up to 80 pF. A capacitance diaphragm pressure transducer and a standard pressure source (Rusca 2465 piston gauge) are connected to the interface to confirm the analysis.