Effects of processing parameters on processing performances of ultrasonic vibration-assisted micro-EDM
Effects of processing parameters on processing performances of ultrasonic vibration-assisted micro-EDM
复制标题
加工参数对超声振动辅助微细电火花加工性能的影响
DOI：
10.1007/s00170-020-06357-9
复制
发表时间：
2020-11-16
影响因子：
3.4
通讯作者：
Zhang, Qinhe
中科院分区：
文献类型：
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作者：
Xing, Qixuan;Yao, Zhenyang;Zhang, Qinhe
为提高钛合金大深径比微孔的加工效率和加工精度，采用超声振动辅助微细电火花加工技术。它可以提高加工过程中的有效放电比，促进冲蚀产物的去除。与非超声振动辅助的大深径比钛合金微细电火花加工相比，当超声振幅为6 μm时，材料去除率（MRR）提高了2.4倍，刀具相对磨损率（RTWR）降低了65.8%，锥度角（θ）降低了73%，过切（OC）降低了32%。在单因素实验的基础上，研究了加工参数（脉冲宽度、脉冲间隔、峰值电流、超声振幅）对加工效果的影响规律和机理。然后，在正交试验的基础上，对超声振动辅助微细电火花加工工艺进行了优化研究。通过信噪比（SNR）分析，得到MRR、RTWR、θ、OC的最佳处理参数组合。对实验结果进行回归分析和方差分析，建立超声振动辅助微细电火花加工工艺模型。验证实验证明了单目标优化结果和过程模型的可靠性。
To improve the processing efficiency and precision of micro-holes with a large depth-to-diameter ratio on titanium alloy, ultrasonic vibration-assisted micro-electrical discharge machining (micro-EDM) is adopted. It could improve the effective discharge ratio in the machining process and promote the removal of erosion products. Compared with the non-ultrasonic vibration-assisted micro-EDM machining of a large depth-to-diameter ratio on titanium alloy, when the ultrasonic amplitude was 6 μm, material removal rate (MRR) was increased by 2.4 times, relative tool wear rate (RTWR) was reduced by 65.8%, taper angle (θ) was reduced by 73%, and overcut (OC) was reduced by 32%. Based on the single factor experiment, this paper studied the influence rule and mechanism of processing parameters (pulse width, pulse interval, peak current, and ultrasonic amplitude) on the machining effect. Then, based on the orthogonal experiment, the optimization research on the processing technology of ultrasonic vibration-assisted micro-EDM was studied. The optimal processing parameter combination of MRR, RTWR,θ, and OC was obtained by signal-noise ratio (SNR) analysis. And regression analysis and analysis of variance were performed on the results, and the process models of ultrasonic vibration-assisted micro-EDM were established. The verification experiment proved the reliability of the single objective optimization result and the process model.