本文關(guān)鍵詞：電鍍電極絲電火花線切割及螺旋電極電火花小孔加工研究　出處：《太原理工大學(xué)》2015年碩士論文　論文類型：學(xué)位論文

  更多相關(guān)文章： 高速走絲線切割 電鍍 電極絲 電火花小孔加工 螺旋電極

【摘要】：電火花加工因其獨(dú)有的優(yōu)勢(shì)，在工業(yè)上具有著不可替代的作用,由于其加工特點(diǎn)，對(duì)電極的機(jī)械性能要求較低，這就使得對(duì)電極的各種處理成為可能。本文針對(duì)電火花加工的兩個(gè)常見問題，提出改進(jìn)電極的解決方案。電火花加工的兩個(gè)常見問題是： (1)高速走絲線切割電極絲損耗較快、壽命較低。由電火花加工本質(zhì)決定，在高速走絲線切割中電極絲的損耗不可避免，又因電極絲循環(huán)使用，所以它會(huì)隨著加工而不斷變細(xì)最終斷裂，影響了高速走絲線切割的正常進(jìn)行。本文提出電極絲補(bǔ)償法，以降低電極絲損耗，最終達(dá)到提高電極絲壽命的目的。文中主要通過電鍍方法來補(bǔ)償電極絲損耗，分析了電鍍對(duì)電極絲的影響并設(shè)計(jì)電鍍過程。選Cu為電鍍材料，分別進(jìn)行了電鍍實(shí)驗(yàn)和電鍍前后電極絲線切割加工實(shí)驗(yàn)，通過電子顯微鏡和掃描電鏡觀察，對(duì)比了不同電極絲的表面形態(tài)，直觀的說明了電鍍Cu有利于保護(hù)電極絲表面；又通過能譜分析對(duì)不同電極絲表面所含元素進(jìn)行分析，從所含元素角度說明了電鍍電極絲補(bǔ)償?shù)目尚行�；之后使用Ansys仿真軟件，得出了電極絲放電瞬間的溫度分布云圖，分析了放電后的散熱過程，結(jié)合焓的運(yùn)算得到放電瞬間熱量傳導(dǎo)情況，得出鍍Cu后理論上只有10%左右的熱量傳遞到電極絲上，大大減小了電極絲基體上的放電凹坑，對(duì)比了銅鉬結(jié)合界面處放電點(diǎn)散熱情況和單獨(dú)鉬表面散熱情況，得到了各時(shí)間點(diǎn)的最高溫度圖，通過計(jì)算可知前者放電后散熱速度是后者的1.5倍左右。上訴分析說明電鍍電極絲可以提高其使用壽命。文中還對(duì)電鍍法補(bǔ)償電極絲進(jìn)行了進(jìn)一步理論分析，提出電鍍補(bǔ)償法的部分改進(jìn)措施。最后提出附著法和復(fù)合電鍍法兩種補(bǔ)償電極絲損耗的方法，簡(jiǎn)單分析了它們的可行性。 (2)電火花小孔加工一直存在排屑困難，，加工速度低的問題，因此提出螺旋電極電火花小孔加工方法，螺旋電極可使排屑容易，加工速度提高。分析了使用螺旋電極后放電間隙內(nèi)流體的運(yùn)動(dòng)狀態(tài)，使用Fluent仿真軟件分別得出螺旋電極和普通電極間隙區(qū)域壓力場(chǎng)和速度場(chǎng)，通過對(duì)比得出螺旋電極有利于排屑的結(jié)論。最后采用D703F高速電火花小孔加工機(jī)床進(jìn)行實(shí)驗(yàn)，實(shí)驗(yàn)結(jié)果表明，螺旋電極電火花小孔加工速度最高可提高20%。文中還對(duì)實(shí)驗(yàn)所用螺旋電極做了詳盡的分析，提出了改進(jìn)措施和進(jìn)一步研究的方向。
[Abstract]:Because of its unique advantages, EDM has an irreplaceable role in industry, because of its processing characteristics, the mechanical properties of the electrode requirements are low. This makes it possible to deal with various kinds of electrodes. In this paper, two common problems of EDM are proposed to improve the solution of electrode. The two common problems of EDM are as follows: Due to the nature of EDM, the loss of electrode wire is inevitable in high speed wire walking wire cutting, and it is also due to the recycling of electrode wire. Therefore, it will continue to finer and eventually break with the processing, which affects the normal conduct of high-speed wire cutting. In this paper, the electrode wire compensation method is proposed to reduce the loss of electrode wire. Finally, the purpose of prolonging the electrode wire life is achieved. In this paper, the loss of electrode wire is mainly compensated by electroplating method. The influence of electroplating on electrode wire is analyzed and the electroplating process is designed. Copper is selected as electroplating material. Electroplating experiment and wire cutting experiment before and after electroplating were carried out respectively. The surface morphology of different electrode wire was compared by electron microscope and scanning electron microscope. It is intuitively explained that Cu plating is beneficial to protect the surface of electrode wire. The elements contained on the surface of different electrode wires were analyzed by energy spectrum analysis, and the feasibility of the compensation of electroplated electrode wires was explained from the point of view of the elements contained. Then using Ansys simulation software, the temperature distribution cloud diagram of the electrode wire discharge moment is obtained, the heat dissipation process after the discharge is analyzed, and the heat conduction situation of the discharge moment is obtained by combining the calculation of the enthalpy. It is concluded that only about 10% of the heat is transferred to the electrode wire after Cu plating, which greatly reduces the discharge pit on the electrode wire matrix. The heat dissipation of the discharge point at the interface between copper and molybdenum was compared with that of the single molybdenum surface, and the maximum temperature diagram of each time point was obtained. The results show that the heat dissipation rate of the former is about 1.5 times that of the latter. The appeal analysis shows that the electroplating electrode wire can improve its service life. Further theoretical analysis of the electroplating compensation electrode wire is also carried out in this paper. In the end, two methods of compensating electrode wire loss by adhesion method and composite electroplating method are put forward, and their feasibility is simply analyzed. (2) there is always the problem of difficult chip removal and low machining speed in EDM. Therefore, the method of EDM machining with helical electrode is put forward, which can make chip removal easy. The flow state in the discharge gap after the use of spiral electrode is analyzed and the pressure field and velocity field in the gap region of spiral electrode and common electrode are obtained by Fluent simulation software. The conclusion that spiral electrode is advantageous to chip removal is obtained by contrast. Finally, D703F high speed EDM machine tool is used to carry out experiments, and the experimental results show that. The maximum machining speed of helical electrode EDM small hole can be increased by 20%. The helical electrode used in the experiment is analyzed in detail and the improvement measures and the direction of further research are put forward.
【學(xué)位授予單位】：太原理工大學(xué)
【學(xué)位級(jí)別】：碩士
【學(xué)位授予年份】：2015
【分類號(hào)】：TG484

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