基于流体动力断弧的高速电弧放电加工  

High-speed Electrical Arc Machining Based on Hydrodynamic Arc Breaking Mechanism

作　　者：赵万生[1] 顾琳[1] 徐辉[1] 李磊[1] 向小莉[1] 

机构地区：[1]上海交通大学机械与动力工程学院机械系统与振动国家重点实验室,上海200240

出　　处：《电加工与模具》2012年第5期50-54,共5页Electromachining & Mould

摘　　要：提出了一种可用于难加工材料大余量高速蚀除的新的放电加工方法——基于流体动力断弧的高速电弧放电加工。与传统的电火花加工方法相比,高速电弧放电加工采用具有更高能量密度的电弧放电而不是火花放电来实现材料的蚀除;与其他利用电弧进行材料去除的工艺方法相比,高速电弧放电加工可使用特殊设计的成形电极实现强制多孔内充液,从而获得三维复杂型腔的沉入式加工能力,因此具有更广泛的应用前景。初步实验表明,对于镍基高温合金等难切削材料,高速电弧放电加工的材料去除率(MRR)远高于传统的电火花加工,甚至高于铣削加工。例如:加工镍基高温合金(GH4169)的材料去除率可达11 300 mm3/min,而电极损耗率(TWR)低于3%。由此可见,高速电弧放电加工在难切削材料的高效去除加工方面具有明显的技术优势。In order to remove the difficult-to-cut materials efficiently, a novel high-speed electrical arc machining process named High-speed Electrical Arc Machining （HEAM） was proposed. Compared with conventional EDM process, the HEAM process removes the work piece materials with arc, a spe-cial plasma column which has a much higher energy density than that of conventional discharging. Un-like other machining processes which also use arcing to remove materials, the HEAM utilizes a specific arc moving/breaking mechanism named hydrodynamic arc moving mechanism which enables this pro- cess performing die-sinking machining to achieve 3D features directly by using a special designed elec-trode with multi hole inner flushing to prevent the arc damage during machining. The preliminary experiments demonstrated that the material removal rate of the HEAM process is extremely higher than that of the traditional EDM and even the milling process. Take Inconel-718 as an example, the MRR can exceed 11 300 mm^3/min. The tool wear ratio is less than 3%. Obviously, it is a promising machining technology that can remove the difficult-to-cut materials with incredibly high efficiency. Besides its high efficiency, HEAM is also an environment-friendly process because it uses water-based working dielectric rather than hydrocarbon working fluids.

关 键 词：高速电弧放电加工 流体动力断弧 多孔内冲液 镍基高温合金 

分 类 号：TG661[金属学及工艺—金属切削加工及机床]