超声混粉电火花加工热力学仿真及表面形貌研究  

Thermodynamic simulation and surface morphology study on ultrasonic powder mixing EDM

作　　者：董颖怀[1] 张少剑 王岩[1] 牛跃博 周文 DONG Yinghuai;ZHANG Shaojian;WANG Yan;NIU Yuebo;ZHOU Wen(College of Mechanical Engineering,Tianjin University of Science and Technology,Tianjin 300222,CHN)

机构地区：[1]天津科技大学机械工程学院,天津300222

出　　处：《制造技术与机床》2024年第1期164-170,共7页Manufacturing Technology & Machine Tool

基　　金：国家自然科学基金青年基金项目(51505334);天津市自然科学基金项目(18JCYBJC88900)。

摘　　要：为了研究超声振动和混粉对电火花加工的影响,基于传热理论,结合超声和混粉特性建立了超声混粉电火花传热模型。基于建立的传热模型对超声混粉电火花加工去除材料过程进行瞬态热力学仿真,并通过实验验证了仿真结果的准确性。通过仿真和实验分析了普通电火花、超声电火花、混粉电火花和超声混粉电火花四种加工方式,结果表明超声混粉电火花加工效率比普通电火花加工效率提高了23%。加入混粉和施加超声可以减少加工表面积碳,提高表面质量;可以使放电凹坑变得更加规则,使表面粗糙度降低。混粉电火花加工相对于普通电火花加工其表面粗糙度平均降低了8.9%,超声混粉电火花表面粗糙度相对于普通电火花平均降低了4.3%。In order to study the effects of ultrasonic vibration and powder mixing on EDM,an ultrasonic powder mixing EDM heat transfer model was established based on heat transfer theory,combining ultrasonic and powder mixing characteristics.Based on the established heat transfer model,a transient thermodynamic simulation of the material removal process by ultrasonic powder mixing EDM was carried out,and the accuracy of the simulation results was verified through experiments.The simulation and experimental analysis of the four machining methods,namely,ordinary EDM,ultrasonic EDM,powder mixing EDM and ultrasonic powder mixing EDM,show that the efficiency of ultrasonic powder mixing EDM is 23%,higher than that of ordinary EDM.The addition of mixed powder and the application of ultrasound can reduce carbon build-up on the machined surface and improve surface quality.The addition of the powder mix can make the discharge craters more regular,resulting in a reduction in surface roughness.The average reduction in surface roughness is 8.9%,compared to normal EDM.The average reduction in surface roughness of ultrasonic powder blending EDM compared to normal EDM is 4.3%.

关 键 词：超声振动 混粉 温度场 表面形貌 高斯热源 

分 类 号：TG66[金属学及工艺—金属切削加工及机床]