横轴布局微细电火花加工机床

介绍了作者研制的微细电火花加工实验样机及部分实验结果.该机床采用横轴布局的主轴结构;应用了先进的线电极电火花磨削法制作微细轴;采用了驰张式微能放电电源;以去离子水作为加工工作液.经实验,加工出了部分微细轴和微孔.     

衡量模具加工精度的一个重要的尺度——电火花电源的低电极损耗

高精度模具加工除了与机床本身精度有关外电火花电源起重要作用。电极损耗性能与生产率、粗糙度等性能相比更起关键作用。此文论述了在保证同样的电极损耗下,性能优良的电极损耗将使粗糙度更细、放电间隙更小、生产率更高。在例举若干较高的电极损耗指标后提出了评审某电源的电极损耗性能高低的标准。     

凸凹球面零件模具的回转展成电加工工艺

介绍了一种用于凸凹球面零件模具加工的回转展成电加工方法.该方法通过电火花加工、电解加工方法的综合应用,不但可以在各种淬过火的模具材料,甚至在硬质合金上加工出不同曲率半径的凸凹球面,而且还可达到很高的精度和好的表面粗糙度.本文主要对这一工艺的原理和加工装置进行必要的论述.     

大面积镜面电火花加工的实验研究

介绍了大面积镜面电火花加工法现状.通过改变混粉工作液中微粉的种类、浓度、加工参数以及加工面积进行了工艺试验.验证了混粉电火花加工的确能改善表面粗糙度.     

电火花高速小孔加工技术及其应用

八十年代初,日本首先成功地发展了高速电火花小孔加工技术.该技术以其独特优异的加工性能,受到了世界各国有关行业的普遍重视.被认为是电加工领域继电火花成型加工、电火花线切割加工之后的第三大支柱.     

大面积镜面电火花加工法

介绍在通常电火花加工的加工液中(煤油)添加一定比例的硅(Si)等粉末,以提高放电的分散性、稳定性,使电火花加工的大面积表面质量和加工性能有很大的改善.     

无动力地理式污水处理的应用分析

从无动力地理式生活污水处理装置的基本原理以及应用范围入手，分析了其用来处理小型生活污水的优缺点，提出了处理小型生活污水处理应走厌氧－好氧相结合之路的观点。     

全电动式围油栏布放装置研究

针对传统液压控制式围油栏布放装置的不足提出了一种全新驱动型式的围油栏布放装置,该装置由卷筒总成、支撑架、三合一电机系统、充吸气机、电气控制系统、遥控器、托辊支架等组成,用于卷绕型式储存的围油栏的布放与回收。它采用全电力驱动型式取代传统的液压驱动,安装方便、占用空间小,成本低、操作方便且无污染。     

填埋场渗漏检测高压直流电法等效电路模型的建立

通过对400V、350V、300V高压直流工作电压下小型模拟填埋场实验数据的分析 ,提出了简化的模型等效电路 .由于高密度聚乙烯(HDPE)衬层的存在使得模型具有了整流特性 ,其电容大小将随着衬层面积和供电电压的增加而增加 ;供电电极的接触电阻与大地的电阻率成正比 ,与电极的粗细及入土深度有关 .同时 ,接触电阻主要由电极附近的土壤电阻决定 ,大于10倍电极半径以外的土壤对接触电阻的影响不超过全部电阻的10% ,故降低电极附近土壤的电阻率可有效地降低电极的接触电阻 .     

电火花成型机床改造的探讨

1 我国电火花成型机床沿革简述电火花加工技术诞生半个多世纪以来,从理论研究、工艺实验及其设备的功能、效率、结构、造型、可靠性、稳定性、价格和产量等诸多方面,都有了极快的进展,特别是九十年代以来,其发展一日千里,渐臻完善.     

Effect of process parameters on the performance of EDM process with ultrasonic assisted cryogenically cooled electrode

In this work the parametric study on EDM process using ultrasonic assisted cryogenically cooled copper electrode (UACEDM) during machining of M2 grade high speed steel has been performed. Electrode wear ratio (EWR), material removal rate (MRR) and surface roughness (SR) was the three parameters observed. Discharge current, pulse on time, duty cycle and gap voltage were the controllable process variables. The effect of process variables on EWR, MRR and SR has been analyzed. The MRR, EWR and SR obtained in EDM process with normal electrode, cryogenically cooled electrode and ultrasonic assisted cryogenically cooled electrode have been compared. EWR and SR were found to be lower in UACEDM process as compared to conventional EDM for the same set of process parameters, while MRR was at par with conventional EDM process. The surface integrity of work piece machined by UACEDM process has been found to be better as compared to conventional EDM process. The shape of the electrode has also been measured and it was found that the shape retention was better in UACEDM process as compared to conventional EDM process. Thus in the present work UACEDM process has been established to be better than conventional EDM process due to better tool life, tool shape retention ability and better surface integrity.     

Analysis of micro-cracks on machined surfaces in dry electrical discharge machining

Micro-crack formation in the heat affected zone in EDM is a common phenomenon and many measures have been perceived to minimize their occurrence. This paper presents a comprehensive and quantitative analysis of micro-crack formation, in terms of length, number and orientation of micro-cracks formed on the machined surfaces. The influence of processing conditions on crack formation is studied using the observations under scanning electron microscope (SEM). The results indicate that the micro-crack formation is the best represented in terms of average crack length. Statistical analysis of the results shows that pulse off-time (T_off), current (I), voltage (V) and electrode rotation speed (N) significantly influence the average crack length in both wall and bottom regions of the machined hole. In dry EDM, micro-crack formation occurs due to segregation of elements in the work surface and inter-diffusion of elements between work, and shield. A comparison of crack formation with the liquid dielectric EDM shows that average length and number density of micro-cracks were lower in the dry EDM than those in the liquid dielectric EDM.     

Study of ultrasonic assisted cryogenically cooled EDM process using sintered (Cu–TiC) tooltip

In most EDM operations, the maximum contribution in the total operation cost is the tool cost. Electrode wear is a major problem in EDM process. Therefore, in this paper, the process performance of sintered copper (Cu)–titanium carbide (TiC) electrode tip in ultrasonic assisted cryogenically cooled electrical discharge machining (UACEDM) has been studied. The performance parameters studied in this paper are electrode wear ratio (EWR), material removal rate (MRR), surface roughness (SR), out of roundness and surface integrity. The process parameters considered in this study are discharge current, pulse on time, duty cycle and gap voltage. Cermet was fabricated, having copper content of 75% and titanium carbide content of 25%, by mixing, pressing, and sintering. The performance of the newly formed cermet electrode tip is compared with conventional copper electrode tip for UACEDM process and analyzed. It has been observed that EWR and out of roundness decreases when cermet electrode tip is used as compared to conventional tooltip. It has also been observed that MRR and SR increase when cermet tooltip is used. The surface cracks density and crack width on workpiece machined by cermet tooltip have been found to be lesser as compared to the specimen machined by conventional tooltip.     

Design and tuning of a fuzzy logic controller for micro-hole electrical discharge machining

The design and tuning of a three-input fuzzy logic controller for electrical discharge machining (EDM) of diesel injector spray holes are presented. The tuning process is based on the variable type and discretization level to balance the data precision and computational time for servo motion updates in the fuzzy logic controller and is performed to improve the micro-hole EDM drilling time. The type and number of input parameters are studied to select the gap voltage, spark ratio, and change of spark ratio as input parameters for the fuzzy logic controller. A gain scheduling controller is used as the baseline and shows excellent drilling time in drilling a 1.14 mm thick workpiece using a 150 μm diameter wire electrode. The tuned fuzzy logic controller is comparable with the gain scheduling controller in drilling time and demonstrates its advantages on different EDM drilling configurations, including deep-hole and small-diameter micro-hole drilling. Analysis of EDM pulse trains reveals insights for controller design and identifies requirements for further improvement.     

汽车转向螺母精锻成形技术的研究开发

对汽车转向螺母精锻的成形工艺、模具及电极的设计与制造技术等方面进行了研究探讨,阐述了所解决的主要问题。试生产表明,采用所开发的精锻成形工艺取代转向螺母齿形及外形的切削加工工艺是合理、可行的。     

Surface modification of die steel materials by EDM method using tungsten powder-mixed dielectric

Surface modification by material transfer during electrical discharge machining (EDM) has emerged as a key research area in the last decade. Material may be provided to the machined surface of the workpiece by the eroding tool electrode or by using powder-mixed dielectric. Breakdown of the hydrocarbon dielectric contributes carbon to the plasma channel which may also cause surface modification. The present work has investigated the response of three die steel materials to surface modification by EDM method with tungsten powder mixed in the dielectric medium. Taguchi experimental design technique was used to conduct the experiments on each work material independently. Peak current, pulse on-time and pulse off-time were taken as variable factors and micro-hardness of the machined surface was taken as the response parameter. X-ray diffraction (XRD) and spectrometric analysis show substantial transfer of tungsten and carbon to the workpiece surface and an improvement of more than 100% in micro-hardness for all the three die steels. Presence of tungsten carbide (WC and W₂C) indicates that its formation is taking place in the plasma channel. Machining parameters for the best value of micro-hardness for each work material were found to be the same.     

Machining efficiency of powder mixed near dry electrical discharge machining based on different material combinations of tool electrode and workpiece electrode

Powder mixed near dry electrical discharge machining (PMND-EDM) is a novel electrical discharge machining (EDM) process. It is proposed to further improve the machining efficiency of dry EDM. The principle of material removal in PMND-EDM is illustrated and its deionization principle is proposed. The influence of residual heat on MRR is analyzed. The concept of superfluous residual heat is proposed. The material removal rate (MRR), the main index of machining efficiency for PMND-EDM process, is researched. Single factor experiments are performed to get effect of peak current, pulse on time, pulse off time, flow rate, tool rotational speed, air pressure and powder concentration on MRR under different material combinations of tool electrode and workpiece electrode. Thermal phenomena in PMND-EDM are illustrated. Effect of each process parameter on MRR of PMND-EDM is gotten and analyzed based on the deionization principle of PMND-EDM. Differences in MRR under different material combinations are found out. Brass tool electrode and W18Cr4V workpiece gain higher MRR under most of discharge conditions, while the superiority of copper tool electrode and 45 carbon steel workpiece in MRR arise when there is improper heat dissipation. The difference is analyzed based on the deionization principle of PMND-EDM.     

Thermo-physical modeling of die-sinking EDM process

This paper reports the development of a thermo-physical model for die-sinking electric discharge machining (EDM) process using finite element method (FEM). Numerical analysis of the single spark operation of EDM process has been carried out considering the two-dimensional axi-symmetric process continuum. The analysis is based on more realistic assumptions such as Gaussian distribution of heat flux, spark radius equation based on discharge current and discharge duration, latent heat of melting, etc., to predict the shape of crater cavity and the material removal rate (MRR). Using the developed model, parametric studies were carried out to study the effect of EDM process parameters such as discharge current, discharge duration, discharge voltage and duty cycle on the process performance. Experimental studies were carried out to study the MRR and crater shapes produced during actual machining. When compared with the reported analytical models, our model was found to predict results closer to the experimental results. The thermo-physical model developed can further be used to carry out exhaustive studies on the EDM process to obtain optimal process conditions.     

有机废水的电催化法降解研究现状

阐释了有机废水电催化法降解机理;综述了传统二维电极、新型三维电极电催化降解有机废水的原理及其应用现状,PbO2电极在三维电极处理有机废水中的应用现状、反应机理以及改性PbO2电极的研究进展;最后对未来发展方向进行了展望。