超声振动复合电火花小孔加工系统设计及试验  

Design and experiment of ultrasonic vibration composite EDM small hole drilling system

作　　者：冯冲 倪皓 孙艺嘉[1] 桂淑钰 宫虎[1] FENG Chong;NI Hao;SUN Yijia;GUI Shuyu;GONG Hu(State Key Laboratory of Precision Measuring Technology and Instruments,School of Precision Instrument and Opto-electronics Engineering,Tianjin University,Tianjin 300072,China;School of Sciences,Tianjin Chengjian University,Tianjin 300384,China)

机构地区：[1]天津大学精密仪器与光电子工程学院精密测试技术及仪器国家重点实验室,天津300072 [2]天津城建大学理学院,天津300384

出　　处：《光学精密工程》2022年第14期1694-1703,共10页Optics and Precision Engineering

基　　金：中国博士后科学基金项目(No.2019M651034)。

摘　　要：针对难加工的镍基高温合金小孔加工,设计了一种新颖的超声振动复合电火花小孔高速加工系统,该系统集成了电极超声振动、电极旋转和电极中心出水等功能,可方便地应用于其他电火花加工机床,并在镍基高温合金GH4099材料工件上开展了一系列小孔加工试验。通过改变加工电流和时间,对比材料去除率、电极损耗率和小孔形貌等指标。试验结果表明:超声振动复合加工在小电流加工时,可以有效地提升材料去除率,并减少相对电极损耗率。在同等条件下,当峰值电流为1 A时,使用该系统加工的孔深度较普通电火花加工的提升89.62%;当峰值电流为6 A时,相比于普通电火花加工材料去除率提升46.42%,相对电极损耗率减少了25.85%。该系统具有更稳定的加工过程,为难加工金属电火花精加工提供一种便利、高效的解决方案。A novel ultrasonic-vibration-composite electrical-discharge-machining(EDM)small-hole high-speed machining system is designed for small-hole machining of difficult-to-machine metals,such as nickel-based superalloys.The system can simultaneously realize the functions of electrode ultrasonic vibration,electrode rotation,and water flush out at the center of the electrode.It can be easily employed for other EDM machines.A series of small-hole machining experiments are carried out on the superalloy GH4099.By altering the machining current and time,indexes such as the material removal rate(MRR),tool electrode wear rate(TWR),and hole morphology are compared.The experimental results reveal that ultrasonic-vibration-composite machining can effectively improve the MRR and reduce the relative TWR during low-current machining.Under the same conditions,when the peak current is 1 A,the hole depth processed by this system is 89.62%higher than that of ordinary EDM.When the peak current is 6 A,the MRR increases by 46.42%compared with that for ordinary EDM.The electrode wear rate is reduced by 25.85%.Thus,we can conclude that the proposed system features a notably stable machining process that provides a convenient and efficient solution for EDM finishing of difficult-to-machine metals.

关 键 词：电火花加工 超声振动 GH4099 电极旋转 

分 类 号：TH162[机械工程—机械制造及自动化]