Influence of metal vapor jets from tool electrode on material removal of workpiece in EDM
Influence of metal vapor jets from tool electrode on material removal of workpiece in EDM
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DOI：
10.1016/j.precisioneng.2018.04.012
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发表时间：
2018-07
期刊：
影响因子：
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通讯作者：
Xiaoming Yue;Xiaoming Yue;Xiaodong Yang;M. Kunieda
中科院分区：
文献类型：
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作者：
Xiaoming Yue;Xiaoming Yue;Xiaodong Yang;M. Kunieda
在电火花加工中，刀具电极表面产生的金属蒸汽射流与工件表面碰撞产生的径向流是材料去除机制之一。使用沸点较低的材料制成的工具电极，钢工件单次放电的材料去除率较大。高速摄像机对放电间隙的观察表明，使用沸点较低的工具电极材料，工件上的熔融物质被清除得更明显，并且清除了大量的碎屑。分子动力学模拟结果表明，使用沸点较低的工具电极，从工件中除去的蒸汽原子的径向速度更高，因为工具电极的射流更强。此外，通过导线振动测量了空气中单脉冲放电作用在导线电极上的放电反力。结果表明，涂锌铜丝的放电反作用力大于未涂锌铜丝。由此可见，射流产生的剪切力是电火花加工中材料的去除机制之一。此外，在线材电火花加工中使用镀锌线材电极获得较高材料去除率的原因之一是线材表面的镀锌层易于沸腾。
This paper shows that the radial flow caused by the collision of the metal vapor jets generated from the surfaces of the tool electrode and workpiece serves as one of the material removal mechanisms in electrical discharge machining (EDM). Material removal per single discharge of a steel workpiece was larger using the tool electrode made of materials with lower boiling point. Observation of the discharge gap using a high-speed video camera showed that molten material on the workpiece was swept away more significantly and larger amounts of debris was removed using the tool electrode materials with lower boiling point. The molecular dynamics simulation showed that the radial velocities of the vapor atoms removed from the workpiece were higher using the tool electrode with lower boiling point because the jets from the tool electrode were more intensive. Furthermore, the discharge reaction force acting on the wire electrode in a single pulse discharge in air was measured from the wire vibration. The results showed a larger discharge reaction force using a zinc coated brass wire compared with a non-coated wire. Thus, it can be concluded that the shear force caused by the jets serves as one of the material removal mechanisms in EDM. Furthermore, one of the reasons for the higher material removal rate obtained using zinc coated wire electrode in wire EDM is the ease of boiling of the zinc coating layer on the wire surface.