Multi-channel discharge characteristics cutting by ultra-fine wire-EDM

Compared with a copper wire electrode, molybdenum wire with a poor conductor is usually used as the electrode in high speed wire-cut electrical discharge machining(HSWEDM), so the resistance of an ultra-fine wire cannot be ignored. To study the differences of discharge characteristics between the ultra-fine wire and the conventional diameter wire, the continuous discharge waveform of two kinds of wire electrodes was compared. It was found that there was a multichannel discharge phenomenon in the...     

钛合金TC4电火花诱导可控烧蚀高效磨削技术研究

利用大部分金属尤其是难加工金属的可燃特性,开发一种针对难加工金属材料的新加工工艺——电火花(EDM)诱导可控烧蚀高效磨削技术。采用开槽导电砂轮进行磨削加工,首先利用导电区域与加工材料产生电火花诱导放电并通入助燃氧气,使材料表面产生电火花引燃烧蚀并软化,然后将已烧蚀和软化的材料磨除,对钛合金TC4进行烧蚀磨削试验,并与常规电火花磨削和机械磨削进行对比,分析了材料去除率(RMM)、表面质量和机床主轴电机功率变化等指标。结果表明,在试验条件下,烧蚀磨削在放电利用率提高的同时可获得表面粗糙度为0.59 μm的加工表面,与机械磨削的表面粗糙度值相近,而相同条件下电火花磨削的表面粗糙度为1.29 μm。由于烧蚀后产生了软化层,在切深小于软化层厚度的条件下,相对于电火花磨削和机械磨削状况,烧蚀磨削主轴电机功率相比空载时的增加值分别降低了95.2%和96.8%。此工艺方法可大大提高难加工材料的可磨削性能。     

Machining of a film-cooling hole in a single-crystal superalloy by high-speed electrochemical discharge drilling

Single-crystal superalloys are typical advanced materials used for manufacturing aeroengine turbine blades. Their unique characteristics of high hardness and strength make them exceedingly difficult to machine. However, a key structure of a turbine blade, the film-cooling hole,needs to be machined in a single-crystal superalloy; such machining is challenging, especially considering the increasing levels of machining efficiency and quality demanded by the aeroengine industry. Tube electrode high-speed electrochemical discharge drilling(TSECDD), a hybrid technique of high-speed electrical discharge drilling and electrochemical machining, provides high machining efficiency and accuracy, as well as eliminating the recast layer. In this study, TSECDD is used to machine a film-cooling hole in a nickel-based single-crystal superalloy(DD6). The Taguchi methods of experiment are used to optimise the machining parameters. Experimental results show that TSECDD can effectively drill the film-cooling hole; the optimum parameters that give the best performance are as follows: pulse duration: 12 ls, pulse interval: 30 ls, peak current:6 A, and salt solution conductivity: 3 m S/cm. Finally, a hole is machined by TSECDD, and the results are compared with those obtained by electrical discharge machining. TSECDD is found to be promising for improving the surface quality and eliminating the recast layer.     

钛合金放电诱导可控燃爆烧蚀高效车削

钛合金在放电诱导和助燃氧气的共同作用下能通过自身燃烧反应被蚀除,随着助燃氧气压力增大,钛合金蚀除速度增大,但是当气体压力增大到一定程度时会发生爆炸,影响材料成形精度。针对钛合金放电诱导烧蚀高效车削加工提出了基于可控燃爆机理的新加工理念,即通过定量高压复合低压进气系统以实现钛合金在加工过程中处于可控燃爆状态,以增加钛合金蚀除速度。并与只通入低压氧气的加工方式进行对比试验。结果表明:基于可控燃爆机理的车削加工,在保证加工精度的前提下,通过间歇定量高压助燃氧气实现钛合金燃爆的可控高效加工,其蚀除速度远远高于只通入低压氧气的放电诱导烧蚀车削。     

冰层辅助对电火花-电解复合穿孔的影响

电火花-电解复合穿孔(ECDD)加工方法有望实现难加工材料涡轮叶片气膜冷却孔无重铸层高效加工,为了进一步提升小孔孔壁的加工质量,提出了在工件底部填充冰层的电火花-电解复合穿孔加工新方法。分析了冰层辅助对复合加工过程中两极之间电流电压的波形、复合穿孔的加工效率、小孔的出入口孔径、孔壁重铸层去除等的影响,进行了冰层辅助与无冰层辅助电火花-电解复合穿孔对比试验。试验表明:冰层辅助加工可以在小孔穿透之后形成充分的反向冲液,有效地解决小孔穿透之后的漏液问题。在增加底部停顿时间的基础上,即小孔穿透后管电极到达预设深度继续停留一段时间,延长管电极对孔壁的电解作用时间,可以显著提高重铸层的去除效果,有望实现小孔整个孔壁重铸层的完全去除。     

Effect of assisted transverse magnetic field on distortion behavior of thin-walled components in WEDM process

Machining performance of thin-walled components made by aeronautical difficult-toprocess materials is a significant issue in the aviation manufacturing industry. Although wire electric discharge machining-low speed(WEDM-LS) is one of typical non-contact machining processes without macro cutting force, which does well in removing hardness and brittleness materials via pulsed discharge at high temperature, but few researchers have studied the thermal distortion behavior leading to a considerable g...     

航发涡轮叶片气膜孔的磨削加工实验

针对目前航空发动机涡轮叶片气膜孔加工精度低和重熔层难去除的问题,提出了"电火花打孔、磨削扩孔"的新型气膜孔加工工艺,研制出小孔磨削专用微细CBN砂轮并对电火花气膜孔进行了磨削工艺实验。实验结果表明:经磨削加工后气膜孔圆度降低50.9%,孔径尺寸标准差降低90.7%,表面粗糙度降低65.9%,重熔层被全部去除,证明了航发涡轮叶片气膜孔磨削加工的可行性。     

Breakthrough detection in electrochemical discharge drilling to enhance machining stability

Film cooling holes are widely used in aero-engine turbine blades. These blades feature large numbers of holes with complex angles and require a high level of surface integrity. Electrochemical discharge drilling(ECDD) combines the high efficiency of electrical discharge drilling(EDD) with high quality of electrochemical drilling(ECD). However, due to the existence of a variety of energy for material removal, accurate and timely detection of breakthroughs is fraught with difficulties. An insuffic...     

单晶硅电火花线切割表面损伤层形成机理

 为了研究单晶硅电火花线切割(WEDM)表面损伤层的损伤形式和形成机理,以电火花线切割加工后的单晶硅表面为研究对象,采用表面形貌观察分析及择优腐蚀方法研究了单晶硅经过电火花线切割后的加工表面.研究结果表明单晶硅经电火花放电加工后表面损伤形式分为4种:热损伤、应力损伤、热与应力综合作用损伤及电解/电化学腐蚀损伤.热损伤使得硅表面形成多晶或非晶硅;应力损伤使硅表面产生裂纹;热与应力综合作用会产生小孔效应,且随着放电功率密度的增加,小孔会明显增多;电解/电化学作用会加快损伤区域及杂质元素富集区域的腐蚀.     

一种提高表面完整性的气膜孔成形方法

为了解决目前航空发动机涡轮叶片气膜孔成形工艺存在热影响严重等问题,提出了采用超快激光环切与螺旋扫描的加工方法,设计了一种可实现高效、无热效应气膜孔加工的双激光光源微加工系统,并从作用机理和实际加工过程两方面分析了热效应的产生原因,指出了其中的主要影响因素,然后针对这些因素选用DD6材料进行了工艺参数优化和实验验证.实验结果表明:采用500fs激光与微秒长脉冲激光复合加工的方式可以使精细钻孔的效率提升约10倍,并得到基本无重铸层和微裂纹的涡轮叶片气膜孔;其工艺参数包括扫描速度为2400r/min,重叠率为12%,进给量为5μm,重复频率为20kHz以及0.6Pa同轴吹气.表明超快激光配合合理的工艺参数和加工方式可以实现无热效应气膜孔加工,是一种有效提高气膜孔成形表面完整性的工艺方法.      

超细晶硬质合金加工机理及加工性能

围绕超细晶硬质合金精密磨削加工、在线电解修整磨削加工、电火花加工、超声复合加工、激光复合加工等加工方法,系统综述了超细晶硬质合金的加工机理和加工性能,并展望了超细晶硬质合金高效精密加工未来的研究重点。     

超声磨料对TC4钛合金电火花加工表面质量的影响

为改善TC4钛合金电火花加工表面质量,减少表面微裂纹、重熔层等表面缺陷,提出了基于电极振动的超声磨料电火花复合加工方法。在煤油工作液中混入12g/L的SiC磨料粉,进行了有无超声磨料作用的窄脉冲(脉宽小于1μs)电火花加工的表面粗糙度对比实验研究。实验结果表明:SiC磨料的超声振动作用使零件表面粗糙度Ra由0.5μm降到0.2μm左右;重熔层厚度、表面裂纹的扫描电子显微镜(SEM)照片显示,超声磨料作用使重熔层厚度减薄20～30μm,表面微裂纹得到有效控制;机理分析认为工作液高频振动及磨料对工件的冲击作用,是改善TC4钛合金电火花加工表面质量的主要原因。研究表明磨料的超声振动作用可显著改善TC4钛合金电火花加工的表面质量。     

电火花线切割加工中放电间隙电压变化特性

电火花线切割加工时工具(电极丝)和工件之间的放电电压是对放电加工过程进行实时检测的重要参数.本文在理论分析的基础上,采用正交试验设计,应用极差分析法和方差分析法定量研究了高速走丝电火花线切割加工中放电间隙电压量的变化特性与加工中峰值电流、工件厚度及切割方向之间的关系.研究的结果为准确检测高速走丝电火花线切割加工状态提供了依据.     

气体介质中深小孔电火花加工技术研究

 深小孔加工一直是机械制造领域的难题之一。在分析和研究气体介质中电火花加工技术的基础上,就其在深小孔加工中的应用进行了深入的理论与实验研究。分别用管状圆柱电极和削边电极在通用电火花成形加工机床上成功地加工出直径为2 mm、深径比大于20、锥度小于0.5%的深小孔。研究表明,相对于传统的液中电火花加工,气体介质中电火花加工深小孔具有电极损耗率低、加工过程稳定等特点。而且由于无需庞大的工作液系统,该方法适合于大型零部件上深小孔加工。     

Surface-improvement mechanism of hybrid electrochemical discharge process using variable-amplitude pulses

Superalloys are commonly used in aircraft manufacturing; however, the requirements for high surface quality and machining accuracy make them difficult to machine. In this study, a hybrid electrochemical discharge process using variable-amplitude pulses is proposed to achieve this target. In this method, electrochemical machining (ECM) and electrical discharge machining (EDM) are unified into a single process using a sequence of variable-amplitude pulses such that the machining process realizes both good surface finish and high machining accuracy. Furthermore, the machining mechanism of the hybrid electrochemical discharge process using variable-amplitude pulses is studied. The mechanism is investigated by observations of machining waveforms and machined surface. It is found that, with a high-frequency transformation between high- and low-voltage waveforms within a voltage cycle, the machining mechanism is frequently transformed from EDM to pure ECM. The critical discharge voltage is 40 V. When pulse voltages greater than 40 V are applied, the machining accuracy is good; however, the surface has defects such as numerous discharge craters. High machining accuracy is maintained when high-voltage pulses are replaced by low-voltage pulses to enhance electrochemical dissolution. The results indicate that the proposed hybrid electrochemical discharge process using variable-amplitude pulses can yield high-quality surfaces with high machining accuracy.     

Effect of tube-electrode inner diameter on electrochemical discharge machining of nickel-based superalloy

Nickel-based superalloys are widely employed in modern aircraft engines because of their excellent material characteristics, particularly in the fabrication of film cooling holes. How-ever, the high machining requirement of a large number of film cooling holes can be extremely chal-lenging. The hybrid machining technique of tube electrode high-speed electrochemical discharge drilling (TEHECDD) has been considered as a promising method for the production of film cooling holes. Compared with any single machining process, this hybrid technique requires the removal of more complex machining by-products, including debris produced in the electrical discharge machin-ing process and hydroxide and bubbles generated in the electrochemical machining process. These by-products significantly affect the machining efficiency and surface quality of the machined prod-ucts. In this study, tube electrodes in different inner diameters are designed and fabricated, and the effects of inner diameter on the machining efficiency and surface quality of TEHECDD are inves-tigated. The results show that larger inner diameters could effectively improve the flushing condi-tion and facilitate the removal of machining by-products. Therefore, higher material removal efficiency, surface quality, and electrode wear rate could be achieved by increasing the inner diam-eter of the tube electrode.     

飞秒激光能量密度对镍基合金重铸层和加工效率的影响

以航空发动机叶片制孔为导向,结合飞秒激光对单晶镍基高温合金材料的非热熔性损伤阈值(Φth1)和热熔性损伤阈值(Φth2)特征,研究了飞秒激光能量密度(0Φ44.2J/cm2)对制孔重铸层和加工效率的影响规律。研究结果表明:在Φth1ΦΦth2时,镍基合金经飞秒激光加工后加工侧壁没有出现明显的重铸物;在ΦΦth2时,加工侧壁开始出现重铸物,并随着能量密度的增加,重铸层厚度增大。在试验结果的基础上,建立了飞秒激光单脉冲加工深度与能量密度的定量关系。能量密度越高,飞秒激光单脉冲加工深度越大,加工效率越高。     

三元流闭式叶轮组合电加工技术研究Ⅱ——数控电解预加工

数控电解预加工是组合电加工技术中不可或缺的关键工艺,本文专题论述了三元流闭式叶轮数控电解预加工中阴极及其运动轨迹设计等关键技术。提出了采用多个阴极分区域加工流道的方法,利用先层切再叠加的方法将三维问题简化为二维问题处理而实现阴极加工型面的数值求解。在完成阴极结构优化设计专用工装夹具设计和数控加工程序编制的基础上,以某型三元流闭式叶轮为研究对象进行了加工工艺试验,并加工了符合设计要求的三元流闭式叶轮。试验研究表明,采取数控电解预加工工艺方案能够满足实际生产要求,可提高效率40%,降低电火花加工的电极损耗50%。     

Experimental investigation of rotary sinking electrochemical discharge milling with high-conductivity salt solution and non-pulsed direct current

Electrochemical milling is a modified technique of traditional electrochemical machining (ECM) that can be used to manufacture some helicopter transmission system parts. The use of rotary tools and an inner-jet electrolyte supply pattern can greatly improve the material removal rate (MRR) in a single pass. However, the feed speed is generally limited to minimize the tool wear. To increase the MRR, electrical discharge machining (EDM) is introduced into the electrochemical milling process. The tool rotation is employed to interrupt the discharge and the high-conductivity salt solution and non-pulsed direct current power supply are also adopted to increase ECM, eventually, a new machining method is proposed, which can be called rotary sinking electrochemical discharge milling (RSECD milling). The mechanism of it is explored in this study by analyzing the machined current, MRR, surface morphology, and tool wear at different applied voltages and feed speeds. Besides, the RSECD milling using the tool with a larger diameter is also conducted to further verify the effectiveness. In particular, the MRR can be increased by 742.5% when using the tool with a diameter of 20 mm at the applied voltage of 20 V.     

微粒对放电通道生长的影响机理研究

 混粉电火花加工相对于普通电火花加工能够在小脉冲能量下稳定地进行加工并实现较好的加工质量,是因为悬浮在工作液中的微粒改变了放电通道形成的机制。分析了粉末颗粒对放电间隙电场、放电通道轨迹形成的影响,得出了混粉电火花加工放电过程稳定性提高的重要原因,即悬浮的微粒以及微粒之间的作用增大局部电场强度、改变放电通道的生长模式,从而减少击穿时间和能量消耗,因此在加工稳定性和加工质量上有明显提高。