本文選題：電火花-電解復(fù)合加工 + 微小孔��； 參考：《南京航空航天大學》2016年碩士論文

【摘要】：微小孔電火花-電解復(fù)合加工將電火花加工和電解加工相結(jié)合,在加工中同步復(fù)合電火花高速穿孔和電化學溶解作用,兼具兩者在小孔加工時的優(yōu)勢,具有較高的加工效率和較好的加工精度,并有望實現(xiàn)無重鑄層加工的要求,未來將適合航空發(fā)動機渦輪葉片氣膜冷卻孔的加工需求。渦輪葉片是一種中空零件,其內(nèi)部是復(fù)雜的流道結(jié)構(gòu),流道寬度只有數(shù)毫米,表面設(shè)計有大量氣膜孔與流道連通。當采用電火花-電解復(fù)合加工進行氣膜冷卻孔的加工時,如不能及時檢測工具電極的穿透以停止其進給,很可能造成對內(nèi)部流道結(jié)構(gòu)和另一側(cè)壁面的誤加工,使葉片報廢。因此進行復(fù)合加工的穿透檢測研究是很有必要的。本文開展了微小孔電火花-電解復(fù)合加工穿透檢測及試驗研究。具體研究了電火花-電解復(fù)合加工穿透檢測的判斷原理,得到了基于加工電壓和電流的穿透檢測判據(jù),并基于數(shù)據(jù)采集卡、計算機和LabVIEW軟件搭建了復(fù)合加工的穿透檢測平臺,在平臺上進行了復(fù)合加工穿透檢測試驗,試驗表明平臺具有很高的檢測成功率,并評價了平臺參數(shù)對小孔加工質(zhì)量的影響。論文主要研究內(nèi)容如下:(1)提出了電火花-電解復(fù)合加工穿透檢測的判據(jù)。針對微小孔電火花-電解復(fù)合加工內(nèi)沖液式、浸液與電極旋轉(zhuǎn)相結(jié)合式以及外沖液輔助式三種沖液形式進行了流場的有限元仿真,結(jié)果表明內(nèi)沖液式最適合于電火花-電解復(fù)合加工。在此基礎(chǔ)上進一步對內(nèi)沖液式復(fù)合加工進行了加工電壓電流的波形試驗,在比較了復(fù)合加工電火花效應(yīng)和電解效應(yīng)的不同波形表現(xiàn)后,分析了工件底部未涂覆和涂覆絕緣反襯層兩種情況下復(fù)合加工穿透三個階段(穿透前、穿透瞬間、穿透后)的不同電火花效應(yīng)和電解效應(yīng),提出了基于加工電壓和電流的穿透檢測的判斷準則。(2)搭建了電火花-電解復(fù)合加工穿透檢測平臺。該穿透檢測平臺由硬件平臺和軟件組成,其中硬件平臺基于數(shù)據(jù)采集卡和計算機構(gòu)建,軟件通過LabVIEW編寫。平臺可實現(xiàn)加工電壓電流的數(shù)據(jù)采集、穿透狀態(tài)分析判斷、穿透信號輸出控制機床主軸停止進給三個部分的功能,并基于LabVIEW編程實現(xiàn)上述功能。平臺的結(jié)構(gòu)和設(shè)計簡單,且正常實現(xiàn)了穿透檢測功能。(3)進行了電火花-電解復(fù)合加工穿透檢測試驗研究。本文在搭建的穿透檢測平臺上,分別針對工件底部未涂覆和涂覆絕緣反襯層兩種情況,開展了穿透檢測試驗,試驗評價了兩種情況下的穿透檢測成功率,結(jié)果表明該平臺具有良好的檢測成功率,并分別評價了平臺穿透延時和底部停頓時間兩個參數(shù)對穿出距離、小孔錐度、孔型以及重鑄層的影響,對參數(shù)進行了優(yōu)選。試驗最后分析了工件底部涂覆有絕緣反襯層時,有無穿透檢測對小孔復(fù)合加工孔口形貌及重鑄層殘留的影響,說明穿透檢測對提高復(fù)合加工加工穩(wěn)定性和加工質(zhì)量具有積極的作用。
[Abstract]:Micro hole EDM and ECM combine EDM with ECM. In machining, synchronous EDM high speed perforation and electrochemical dissolution have the advantages of both in small hole machining. It has higher machining efficiency and better machining precision, and it is expected to meet the requirements of non-cast layer machining, which will be suitable for the processing of air-engine turbine blade gas film cooling holes in the future. Turbine blade is a hollow part with a complex flow channel structure with a width of only a few millimeters and a large number of air film holes connected to the runner. When the gas film cooling hole is processed by EDM, if the penetration of the tool electrode can not be detected in time to stop its feed, it may lead to the wrong machining of the internal runner structure and the other side wall, which will lead to the blade scrapping. Therefore, it is necessary to study the penetration detection of composite machining. In this paper, the penetration detection and experimental study of micro-hole EDM-ECM are carried out. The judgment principle of EDM penetration detection is studied in detail, and the penetration detection criterion based on machining voltage and current is obtained. Based on data acquisition card, computer and LabVIEW software, the penetration detection platform of composite machining is built. The penetration test of composite machining on the platform shows that the platform has a high success rate of detection and the influence of platform parameters on the machining quality of small holes is evaluated. The main contents of this paper are as follows: (1) the criterion of EDM penetration detection is proposed. In this paper, the finite element simulation of flow field is carried out for the three kinds of internal efflux, the combination of immersion and electrode rotation, and the external flushing assistant in micro hole EDM combined with electrolytic machining, in which the flow field is simulated by finite element method. The results show that the internal efflux type is the most suitable for EDM-ECM. On the basis of this, the waveform test of voltage and current was carried out on the internal flushing composite machining, and the different waveforms of EDM and electrolytic effect were compared. The different EDM effect and electrolysis effect in the three stages of composite machining penetration (before penetration, penetration moment and after penetration) are analyzed in the case of uncoated and coated insulating backliner on the bottom of workpiece. The judgement criterion of penetration detection based on machining voltage and current is put forward. (2) the platform of EDM penetration detection based on EDM is built. The platform is composed of hardware platform and software. The hardware platform is based on data acquisition card and computer, and the software is written by LabVIEW. The platform can realize the functions of data acquisition of processing voltage and current, analysis and judgement of penetration state, and output of penetration signal to control the spindle of machine tool to stop feeding. The above functions can be realized by programming based on LabVIEW. The structure and design of the platform are simple, and the penetration detection function is realized normally. In this paper, the penetration test is carried out on the platform, which is not coated on the bottom of the workpiece, and the success rate of the penetration detection is evaluated under the two conditions. The results show that the platform has a good success rate of detection, and the influence of the penetration delay and the bottom pause time on the penetration distance, the taper of the hole, the hole shape and the recast layer are evaluated, and the parameters are selected. At the end of the experiment, the influence of penetration detection on the morphology of the hole and the residual of the recast layer is analyzed when the insulating liner is coated on the bottom of the workpiece. It shows that penetration detection has a positive effect on improving the stability and quality of composite machining.
【學位授予單位】：南京航空航天大學
【學位級別】：碩士
【學位授予年份】：2016
【分類號】：TG666

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本文編號：1898429