磁场电火花复合小孔加工机理及仿真实验研究
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摘要
随着机械微型化、精密化、自动化的不断发展,小孔加工越来越困难。尤其是硬脆材料的加工,用传统的加工方法很难达到加工要求。电火花加工属于非接触式加工,避免了对硬度、尺寸、形状的约束,具有很多优点,如加工超硬金属、陶瓷、复杂型腔等,所以电火花高速小孔加工成为目前小孔加工的主要方式之一。但是电火花高速小孔加工存在加工效率较低,加工不稳定等缺点,当小孔加工的深径比较大时,由于排屑困难,这种缺点更加明显。排屑困难引起二次放电,又引起了加工的形位误差,影响产品的性能。为了改善电火花高速小孔加工的工艺,研究者都在不断探索新思路、新方法。目前,国内外学者和工程技术人员已提出了多种复合加工方法,如电火花超声波复合加工、电解电火花复合加工、磨削电火花复合加工、磁场电火花复合加工等。
为了利用单脉冲放电装置,进一步研究磁场电火花复合加工机理,本文根据电火花加工中脉冲电源的工作原理,用protel99SE设计了单脉冲加工电源并做成PCB板。电源以PIC16F877为控制核心,采用MOSFET专用功率驱动芯片TPS2812p,通过编程可实现脉宽2μs以上的单脉冲或连续脉冲电源。
磁场电火花复合小孔加工中,外加磁场的作用方式有加平行磁场和加垂直磁场两种。加平行磁场的复合小孔加工是基于磁场对电蚀微粒的磁化力,改善小孔加工中排屑困难,提高加工速度;而加垂直磁场的复合小孔加工是利用带电粒子在磁场中受到洛伦磁力而改变运动方向,延长运动路径来改善加工效果。本文分别对加平行磁场复合小孔加工和加垂直磁场复合小孔加工的加工速度、表面粗糙度、放电通道的振荡进行了理论分析和相应的试验研究。
在以上理论分析和实验研究的基础上,重点用Fluent软件对平行磁场电火花复合小孔加工的间隙排屑进行了流场仿真。通过仿真得出了深小孔加工中流场的压力、速度分布,并分析了对加工屑蚀除的影响,然后进一步得出了平行磁场电火花复合前后加工屑的运动轨迹、速度及流场中滞留时间的变化。
仿真结果与实验的结论是一致的,通过仿真与试验的对比与分析,进一步证实平行磁场电火花复合能够通过改善排屑情况来提高深小孔的加工性能。
Machining of small hole became more and more difficult by continuous development of machinery in such aspect as miniaturization, precision and automation. Especially hard,brittle metal and non-metallic materials,traditional processing methods is very difficult to achieve the requirements. EDM belongs to non-contact processing, avoiding the constraints of tools on the hardness, size, shape and have many advantages, so high-speed small hole EDM machining has become one of the main ways of processing to small hole at present. However, high-speed small hole EDM machining still has shortcomings. Such as, lower processing efficiency and processing quality of instability. The weaknesses become more pronounced because of debris being driven difficultly when the ratios became large between depth and diameter. Debris stranded in the gap causes secondary discharge, further leads to the processing of form and position errors, that affect product performance seriously. In order to improve high-speed small hole EDM machining process, the researchers are constantly exploring new ideas, new methods. At present, scholars and technicians of domestic and foreign has put forward a variety of compound machining methods, such as ultrasonic, electrolysis, grinding, magnetic combined EDM machining and so on.
In order to research mechanism of magnetic and EDM compound machining with single-pulse discharge devices, a single pulse EDM generator is designed with protel99SE according to the working principle of pulse generator used in EDM processing and made into PCB broad. The core of generator is PIC16f877, it adopts special power amplifier driver IC TPS2812p of MOSFET and can change into any single pulse or continuous pulse generator that pulse width more than two microseconds.
There are two external ways on small hole magnetic field and EDM compound machining: the direction of magnetic field is parallel with the direction of electric field and vertical with the direction of electric field. The former is based on magnetizing force of magnetic field imposing on electric corrosion particles, improve the processing velocity by improving the process of expelling debris. The latter improves performance by imposing Lorentz force on charged particles to change moving direction and prolong for motion tracks. In this paper, processing velocity, surface roughness, discharge channel of two machining are researched and experiments have been study correspondingly.
Based on the above theoretical analysis and experimental studies, the gap expelling debris of the former small hole magnetic and EDM compound drilling is simulated in flow field by fluent software. Field stress, velocity distribution during the small deep-hole processing were obtained, the effect of driving debris was analyzed , then the trajectory, velocity, residence time of particles on after-hybrid and pre-hybrid of the magnetic assisted EDM were simulated.
The simulation results is the same as the experimental conclusion, Compared the simulation results with the experimental results and analysis, further it confirms that Processing Technology can be improved during small deep-hole permanent magnetic and EDM compound machining.
为了利用单脉冲放电装置,进一步研究磁场电火花复合加工机理,本文根据电火花加工中脉冲电源的工作原理,用protel99SE设计了单脉冲加工电源并做成PCB板。电源以PIC16F877为控制核心,采用MOSFET专用功率驱动芯片TPS2812p,通过编程可实现脉宽2μs以上的单脉冲或连续脉冲电源。
磁场电火花复合小孔加工中,外加磁场的作用方式有加平行磁场和加垂直磁场两种。加平行磁场的复合小孔加工是基于磁场对电蚀微粒的磁化力,改善小孔加工中排屑困难,提高加工速度;而加垂直磁场的复合小孔加工是利用带电粒子在磁场中受到洛伦磁力而改变运动方向,延长运动路径来改善加工效果。本文分别对加平行磁场复合小孔加工和加垂直磁场复合小孔加工的加工速度、表面粗糙度、放电通道的振荡进行了理论分析和相应的试验研究。
在以上理论分析和实验研究的基础上,重点用Fluent软件对平行磁场电火花复合小孔加工的间隙排屑进行了流场仿真。通过仿真得出了深小孔加工中流场的压力、速度分布,并分析了对加工屑蚀除的影响,然后进一步得出了平行磁场电火花复合前后加工屑的运动轨迹、速度及流场中滞留时间的变化。
仿真结果与实验的结论是一致的,通过仿真与试验的对比与分析,进一步证实平行磁场电火花复合能够通过改善排屑情况来提高深小孔的加工性能。
Machining of small hole became more and more difficult by continuous development of machinery in such aspect as miniaturization, precision and automation. Especially hard,brittle metal and non-metallic materials,traditional processing methods is very difficult to achieve the requirements. EDM belongs to non-contact processing, avoiding the constraints of tools on the hardness, size, shape and have many advantages, so high-speed small hole EDM machining has become one of the main ways of processing to small hole at present. However, high-speed small hole EDM machining still has shortcomings. Such as, lower processing efficiency and processing quality of instability. The weaknesses become more pronounced because of debris being driven difficultly when the ratios became large between depth and diameter. Debris stranded in the gap causes secondary discharge, further leads to the processing of form and position errors, that affect product performance seriously. In order to improve high-speed small hole EDM machining process, the researchers are constantly exploring new ideas, new methods. At present, scholars and technicians of domestic and foreign has put forward a variety of compound machining methods, such as ultrasonic, electrolysis, grinding, magnetic combined EDM machining and so on.
In order to research mechanism of magnetic and EDM compound machining with single-pulse discharge devices, a single pulse EDM generator is designed with protel99SE according to the working principle of pulse generator used in EDM processing and made into PCB broad. The core of generator is PIC16f877, it adopts special power amplifier driver IC TPS2812p of MOSFET and can change into any single pulse or continuous pulse generator that pulse width more than two microseconds.
There are two external ways on small hole magnetic field and EDM compound machining: the direction of magnetic field is parallel with the direction of electric field and vertical with the direction of electric field. The former is based on magnetizing force of magnetic field imposing on electric corrosion particles, improve the processing velocity by improving the process of expelling debris. The latter improves performance by imposing Lorentz force on charged particles to change moving direction and prolong for motion tracks. In this paper, processing velocity, surface roughness, discharge channel of two machining are researched and experiments have been study correspondingly.
Based on the above theoretical analysis and experimental studies, the gap expelling debris of the former small hole magnetic and EDM compound drilling is simulated in flow field by fluent software. Field stress, velocity distribution during the small deep-hole processing were obtained, the effect of driving debris was analyzed , then the trajectory, velocity, residence time of particles on after-hybrid and pre-hybrid of the magnetic assisted EDM were simulated.
The simulation results is the same as the experimental conclusion, Compared the simulation results with the experimental results and analysis, further it confirms that Processing Technology can be improved during small deep-hole permanent magnetic and EDM compound machining.
引文
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