电火花线切割加工钛合金表面微槽工艺参数研究

为了研究电火花线切割工艺参数(脉冲宽度、脉冲间隔、峰值电流、极间电压)对TC4钛合金加工的影响规律,本文通过一组四因素四水平正交试验,以切割速度、加工精度作为评价指标,通过极差分析法研究各工艺参数对钛合金加工的影响程度.试验结果表明:脉冲宽度对切割速度的影响是最大的,峰值电流对加工精度的影响是最大的.在脉冲宽度为24μ...     

3Cr2W8V电火花成形加工工艺指标试验研究

通过电火花成形加工3Cr2W8V的实验研究,探索了峰值电流、脉冲宽度和脉冲间隔对电火花成形加工的加工速度、电极损耗的影响,总结出3Cr2W8V电火花成形加工合理的加工参数.实验表明:峰值电流为18.4 A、脉冲宽度为130 μs、脉冲间隔为24 μs时,可以进行高效加工.这对模具制造中采用电火花成形加工具有一定的指导意义.     

纯铜窄缝式电极电火花线切割加工试验研究

窄缝式电极可以代替凹槽式电极用于电火花成形微凸起结构.为研究纯铜窄缝式电极电火花线切割加工性能的影响规律,以峰值电流、脉冲宽度、脉冲间隔、间隙电压为试验因素,设计进行了正交试验.研究了各试验因素对切缝宽度、切割速度的影响关系,采用信噪比和灰关联度分析方法对多工艺目标进行优化参数组合.试验结果表明:各因素对切缝宽度影响强弱依次为,间隙电压、脉冲宽度、脉冲间隔、峰值电流;对切割速度影响强弱依次为,脉冲宽度、脉冲间隔、间隙电压、峰值电流,其中脉冲宽度、脉冲间隔对切割速度的影响起主导作用.脉冲宽度20μs、脉冲间隔40μs、峰值电流8档、间隙电压6档为最优组合参数,为纯铜窄缝式电极的制作提供理论指导.     

4Cr5MoVSi电火花加工试验特征规律研究

采用紫铜工具电极,在峰值电流为4-24A、脉冲宽度为25-200μs、加工电压为80-200V的电参数范围内,综合应用因子试验和正交试验方法,对难加工材料4Cr5MoVSi进行了电火花加工试验。在进行电加工基础特征规律分析的基础上,考查了电参数对加工速度、双边侧面放电间隙、电极损耗的影响,并对电火花加工机理进行了分析。研究结果表明:采用紫铜电极电火花加工4Cr5MoVSi,在本试验范围内,峰值电流Ip与脉冲宽度ti、加工电压U、脉冲间隔t0存在一定的交互作用;与其它三个因素相比,峰值电流对加工速度、电极损耗、双边侧面放电间隙的影响更显著;随脉冲宽度和加工电压的增大,电极损耗逐渐减小。     

基于电火花-电解复合加工的钨材料微小孔加工研究

为实现钨材料微小孔高效、高质量加工,提出对钨材料采用低电导率盐溶液电火花-电解复合加工方式。通过实验分析发现,相比于纯电火花加工,在相同的加工环境下对钨材料进行电火花-电解复合加工效率提升为67μm/s。在此基础上,探究了电参数(脉冲宽度、脉冲间隙、峰值电流)、溶液浓度对电火花-电解复合加工的影响规律,并通过正交实验确定最优参数为脉冲宽度2μs,脉冲间隙2μs,峰值电流2 A,电解液浓度10 g/L。     

QT700-2电火花加工工艺试验特征规律研究

综合应用单因素实验和正交实验对QT700-2进行电火花加工试验,在分析电火花加工QT700-2基础特征规律之上,考查了电规准对材料去除率、电极损耗等的影响规律。研究结果表明,采用紫铜电极负极性标准切入加工QT700-2时,在试验范围内,峰值电流对加工速度和电极损耗的影响最为显著;脉冲宽度在25～400μs范围内存在一个使加工速度最快的脉冲宽度ti;峰值电流虽然可以提高加工效率,但是会急剧加速电极损耗,在保证较低相对损耗比的同时提高加工效率,应首先考虑提高脉冲宽度。     

电火花加工实验数学模型的建立

用正交试验法对电火花加工中的峰值电流、脉冲宽度、脉冲间隔进行设计,在大量实验数据的基础上,采用最小二乘法建立实用的多种材料的电火花加工实验数学模型。     

镍基高温合金IN718电火花加工初步试验研究

镍基合金具有优良的性能而获得广泛的应用,本文针对切削加工中存在的刀具损坏严重、加工效率极低的问题,采用与材料的力学性能无关的电火花进行加工,通过对其初步电火花加工实验,研究了峰值电流和脉冲宽度加工参数的影响规律。结果表明,电火花可取得较好的加工效果。表面粗糙度随峰值电流和脉冲宽度的减小而减小,加工表面各向同性。加工表面微观组织由大小不等的熔滴,微小孔洞组成。随脉冲能量增大,重铸现象严重;显微硬度变化不大,无加工硬化现象。     

基于正交试验的电火花加工工艺效果试验分析

通过正交试验分析,探讨电火花成形加工中影响加工效果的主要因素,阐述了脉冲峰值电流、脉冲宽度及脉冲间 隔等对加工速度、加工表面粗糙度及工具电极损耗的影响关系,对解决电火花加工实践中工艺参数优化问题具有一定的 理论和实践意义。     

放电成型加工中的单晶硅材料去除率建模分析与实验研究

在半导体材料放电加工可行性的基础上,分析了影响材料去除率的几个主要因素,其中包括空载电压、峰值电流、脉冲宽度以及脉冲间隔。采用中心组合设计实验,考察峰值电流、脉冲宽度、脉冲间隔这3个因素对单晶Si放电加工的材料去除率的影响,建立了单晶Si放电加工的材料去除率的响应模型,进行响应面分析。方差分析结果表明模型具有很好的拟合程度和适应性。采用满意度函数(DFA)确定了单晶Si放电加工的最佳工艺参数,当峰值电流取18.5A、脉冲宽度取358.62μs、脉冲间隔取20μs时,满意度为0.912,此时材料去除率的最优值为76.26 mm~3/min。用所确定的最佳工艺参数在电火花成型机床上重复多次实验,测得P型单晶硅的平均MRR为73.86 mm~3/min。模型预测结果与最佳工艺参数下的实验结果平均相对误差为3.2%,验证实验表明该模型能实现相应的半导体材料放电加工过程的材料去除率预测。     

不同电规准条件下硬质合金电火花加工性能的研究

通过对硬质合金材料的电火花加工试验,研究了脉冲宽度、峰值电流等电参数对加工效率、电极损耗、加工表面粗糙度等加工性能的影响规律,并分析了其作用机理,提出通过合理配置电参数以改善硬质合金加工性能的工艺原则。     

开环PWM控制储能电容恒流充电方法

针对储能电容闭环PWM控制恒流充电和LC谐振式恒流充电的不足,提出了开环PWM控制储能电容恒流充电方法。通过对充电过程的计算机仿真,得出用于恒流充电开环PWM控制的占空比数据。应用中设计的开关电源将系列占空比数据存入单片机,然后顺序给出进行开环PWM控制,能够给800μF电容快速充电到1000V。根据实际测量的电流波形,对可控的占空比大小和变化趋势作适当的调整,能够控制充电电流达到理想快速短时恒流充电方式。     

TC4钛合金电火花小孔加工多目标优化试验研究

为提升电火花加工TC4钛合金的表面加工质量和加工效率,选取紫铜圆柱电极开展TC4钛合金电火花小孔加工试验,采用正交试验法,以电极相对损耗率、表面粗糙度、工件材料去除体积为工艺指标,分析峰值电流、维持电压、放电脉宽对工艺指标的影响重要性。采用RBF(Radial basis function)神经网络对已有试验数据进行训练,建立放电参数与工艺指标之间的数学预测模型。以该预测模型为适应度函数,将遗传算法与Skyline选择算法结合进行多目标优化仿真,得到最佳工艺指标,最后开展多目标优化验证试验。结果表明：当峰值电流为14 A、维持电压39 V/42 V、放电脉宽102μs/108μs时能够取得最优的加工结果,优化值与试验值误差较小。     

冲击信号测量系统中下限频率的正确选取

本文通过分析冲击信号测量系统下限频率对三种典型冲击信号测量的影响，得出一组冲击信号脉宽及峰值的测试误差与系统下限频率、信号脉宽之间的关系曲线。同时，本文还给出了一套在给定误差的条件下，正确选取冲击信号测量系统下限频率的方法。关键词：     

Influence of machining parameters on surface roughness in finish cut of WEDM

Surface roughness is significant to the finish cut of wire electrical discharge machining (WEDM). This paper describes the influence of the machining parameters (including pulse duration, discharge current, sustained pulse time, pulse interval time, polarity effect, material and dielectric) on surface roughness in the finish cut of WEDM. Experiments proved that the surface roughness can be improved by decreasing both pulse duration and discharge current. When the pulse energy per discharge is constant, short pulses and long pulses will result in the same surface roughness but dissimilar surface morphology and different material removal rates. The removal rate when a short pulse duration is used is much higher than when the pulse duration is long. Moreover, from the single discharge experiments, we found that a long pulse duration combined with a low peak value could not produce craters on the workpiece surface any more when the pulse energy was reduced to a certain value. However, the condition of short pulse duration with high peak value still could produce clear craters on the workpiece surface. This indicates that a short pulse duration combined with a high peak value can generate better surface roughness, which cannot be achieved with long pulses. In the study, it was also found that reversed polarity machining with the appropriate pulse energy can improve the machined surface roughness somewhat better compared with normal polarity in finish machining, but some copper from the wire electrode is accreted on the machined surface.     

Generation of electron beams with adjustable durations of 1.0–0.2 ns and current amplitudes more than 400 A

The conditions for forming subnanosecond electron beams with adjustable pulse durations in the vacuum-diode mode using a SLEP-150 generator were investigated. It was confirmed that the residual air pressure in the diode (～0.1 Torr or less) does not affect the amplitude and duration of the beam current when using a nanosecond voltage pulse. It was shown that increasing the air pressure in the diode from 0.1 to 6.0 Torr leads to a decrease in the full width at half-maximum (FWHM) duration of the electron-beam current from ～1.00 to 0.18 ns and a shorter delay of the beam generation moment relative to the voltage-pulse rise time. It was established that the amplitude of the first peak of the beam current behind the foil remained constant under these conditions. Its value was ≥400 A. It is shown that when the interelectrode gaps are optimal for vacuum diodes, the pulse duration at elevated pressures shortens due to the gap breakdown for a time of ≤200 ps.     

Design and performance of a pulse transformer based on Fe-based nanocrystalline core

A dry-type pulse transformer based on Fe-based nanocrystalline core with a load of 0.88 nF, output voltage of more than 65 kV, and winding ratio of 46 is designed and constructed. The dynamic characteristics of Fe-based nanocrystalline core under the impulse with the pulse width of several microseconds were studied. The pulse width and incremental flux density have an important effect on the pulse permeability, so the pulse permeability is measured under a certain pulse width and incremental flux density. The minimal volume of the toroidal pulse transformer core is determined by the coupling coefficient, the capacitors of the resonant charging circuit, incremental flux density, and pulse permeability. The factors of the charging time, ratio, and energy transmission efficiency in the resonant charging circuit based on magnetic core-type pulse transformer are analyzed. Experimental results of the pulse transformer are in good agreement with the theoretical calculation. When the primary capacitor is 3.17 μF and charge voltage is 1.8 kV, a voltage across the secondary capacitor of 0.88 nF with peak value of 68.5 kV, rise time (10%-90%) of 1.80 μs is obtained.     

重复频率锁定的783 nm飞秒光纤激光器研制

设计并搭建了重复频率长时精确锁定的783 nm飞秒光纤激光器。该激光器基于全保偏非线性干涉环镜(NALM),实现掺铒光纤振荡器锁模脉冲输出,由与脉冲分离器级联的环境稳定掺铒光纤双级放大器进行功率放大,实现了平均功率1.30 W、脉冲宽度130 fs、重复频率77.1 MHz、1 560 nm脉冲输出;通过周期极化铌酸锂(PPLN)光学晶体倍频,获得了平均功率为0.52 W、脉冲宽度为140 fs、783 nm脉冲输出。通过重复频率监测及锁相环技术,进一步将掺铒光纤振荡器的重复频率溯源至参考铷原子钟,12 h内频率抖动峰-峰值为5 mHz、标准偏差为1.2 mHz。该激光器系统具有稳定性高、集成度高、体积小的特点。