放电加工方法及其机理的数值模拟研究综述A Review of Electric Discharge Machining Methods and Numerical Simulation Studies of the Mechanism
周建平,陈小康,李雪芝,周宗杰,董行,汪兵兵,赵一楠
摘要(Abstract):
从数值模拟角度出发,以放电状态作为主要区分点,围绕放电过程中所涉及的放电通道、能量分配比例、放电凹坑和材料去除过程等,归纳总结了目前放电加工方法、电火花和电弧加工机理的研究进展,并预测未来放电加工机理的数值模拟研究趋势.重点围绕等效热源、多物理场和分子动力学复合模拟、电弧加工机理三方面进行研究,以期更加准确地揭示放电加工背后机理,解决电弧加工效率和质量难以兼得的难题.
关键词(KeyWords): 放电加工;数值模拟;加工机理;电火花加工;电弧加工
基金项目(Foundation): 国家自然科学基金“航空薄壁零件低压微弧铣削加工放电通道演化规律与变形抑制方法研究”(52265061);; 新疆维吾尔自治区“天池英才”青年博士项目“高效精密深小孔低压微弧等离子体辅助电解加工方法”(51052300550)
作者(Author): 周建平,陈小康,李雪芝,周宗杰,董行,汪兵兵,赵一楠
DOI: 10.13568/j.cnki.651094.651316.2023.06.12.0002
参考文献(References):
- [1]白基成,刘晋春,郭永丰,等.特种加工[M].北京:机械工业出版社, 2019.
- [2] YUE X M, YANG X D, TIAN J, et al. Thermal, mechanical and chemical material removal mechanism of carbon fiber reinforced polymers in electrical discharge machining[J]. International Journal of Machine Tools and Manufacture, 2018, 133:4-17.
- [3] YUE X M, YANG X D, KUNIEDA M. Influence of metal vapor jets from tool electrode on material removal of workpiece in EDM[J]. Precision Engineering, 2018, 53:278-288.
- [4] CHAKRABORTY S, DEY V, GHOSH S K. A review on the use of dielectric fluids and their effects in electrical discharge machining characteristics[J]. Precision Engineering, 2015, 40:1-6.
- [5] SINGH S, BHARDWAJ A. Review to EDM by using water and powder-mixed dielectric fluid[J]. Journal of Minerals&Materials Characterization&Engineering, 2011, 10(2):199-230.
- [6] PURI A B, BHATTACHARYYA B. An analysis and optimisation of the geometrical inaccuracy due to wire lag phenomenon in WEDM[J]. International Journal of Machine Tools and Manufacture, 2003, 43(2):151-159.
- [7] YAN M T, LAI Y P. Surface quality improvement of wire-EDM using a fine-finish power supply[J]. International Journal of Machine Tools and Manufacture, 2007, 47(11):1686-1694.
- [8]王俊棋.大气和水雾介质中往复走丝线切割加工机理及实验研究[D].哈尔滨:哈尔滨理工大学, 2018.
- [9] KUNIEDA M, YOSHIDA M, TANIGUCHI N. Electrical discharge machining in gas[J]. CIRP Annals-Manufacturing Technology,1997, 46(1):143-146.
- [10] JESWANI M L. Electrical discharge machining in distilled water[J]. Wear, 1981, 72(1):81-88.
- [11] FURUTANIA K, SANETO A, TAKEZAWA H, et al. Accretion of titanium carbide by electrical discharge machining with powder suspended in working fluid[J]. Precision Engineering, 2001, 25(2):138-144.
- [12] ZHAO W S, MENG Q G, WANG Z L. The application of research on powder mixed EDM in rough machining[J]. Journal of Materials Processing Technology, 2002, 129(1):30-33.
- [13] MESHCHERIAKOV G, NOSULENKO V, MESHCHERIAKOV N, et al. Physical and technological control of arc dimensional machining[J]. CIRP Annals-Manufacturing Technology, 1988, 37(1):209-212.
- [14]吴国庆,廖萍,汪希平.电熔爆机床的噪声和电磁辐射测控研究[J].电加工与模具, 2003(6):29-31+70.
- [15]刘姣.电熔爆技术在深台阶孔加工中应用研究[D].西安:西安工业大学, 2013.
- [16]梁楚华,朱志坚,杨明洁.电熔爆技术发展现状及展望[J].现代制造工程, 2004(1):98-100.
- [17]谢得岗.电熔爆加工机理及在内腹孔加工中的应用研究[D].太原:中北大学, 2017.
- [18] HAN F Z, WANG Y X, ZHOU M. High-speed EDM milling with moving electric arcs[J]. International Journal of Machine Tools and Manufacture, 2009, 49(1):20-24.
- [19]王用贤.直流运动电弧铣削加工系统构建与工艺实验[D].北京:清华大学, 2009.
- [20] ZHAO W S, GU L, XU H, et al. A novel high efficiency electrical erosion process-blasting erosion arc machining[J]. Procedia CIRP, 2013, 6(6):621-625.
- [21]徐辉.高速电弧放电加工的工艺特性研究[D].上海:上海交通大学, 2015.
- [22] WANG F, LIU Y H, TANG Z M, et al. Ultra-high-speed combined machining of electrical discharge machining and arc machining[J].Proceedings of the Institution of Mechanical Engineers Part B:Journal of Engineering Manufacture, 2013, 228(5):663-672.
- [23] WANG F, LIU Y H, ZHANG Y Z, et al. Compound machining of titanium alloy by super high speed EDM milling and arc machining[J]. Journal of Materials Processing Technology, 2014, 214(3):531-538.
- [24]张敏.振动辅助电弧铣削加工技术及机理研究[D].济南:山东大学, 2016.
- [25]朱光.高压激励电弧铣削加工技术及机理研究[D].济南:山东大学, 2020.
- [26]梁楚华,周建平,朱志坚,等.短电弧加工技术及其应用[J].现代制造工程, 2007(12):92-93+112.
- [27] ZHOU J P, LIANG C H, TENG W J, et al. Study on rules in material removal rate and surface quality of short electric arc machining process[J]. Advanced Materials Research, 2008, 33/34/35/36/37:1313-1318.
- [28]汪兵兵,周建平,许燕,等.镍基高温合金短电弧铣削加工性能与电极损耗规律研究[J].制造技术与机床, 2015(10):139-143.
- [29] LI X Z, ZHOU J P, WANG K D, et al. Experimental research on machinability of different electrode materials for SEAM of the nickel-based superalloy GH4169[J]. Proceedings of the Institution of Mechanical Engineers Part C:Journal of Mechanical Engineering Science, 2018, 232(24):4528-4537.
- [30]王博.数控短电弧铣削加工工具电极损耗规律研究[D].乌鲁木齐:新疆大学, 2017.
- [31]胡国玉,周建平,毛俊豪.短电弧铣削加工极间流场仿真与试验研究[J].新疆大学学报(自然科学版), 2019, 36(4):387-394.
- [32]王帅帅,李雪芝,陈小康,等.基于定长补偿法的短电弧铣削加工电极补偿研究[J].新疆大学学报(自然科学版)(中英文), 2021,38(2):242-250.
- [33]宋丹,周建平,王恪典. 7075铝合金短电弧铣削加工工艺试验研究[J].新疆大学学报(自然科学版), 2019, 36(4):395-399+405.
- [34]陈小康.短电弧高效铣削加工机理及工艺研究[D].乌鲁木齐:新疆大学, 2021.
- [35]赵万生.先进电火花加工技术[M].北京:国防工业出版社, 2003.
- [36]赵万生,顾琳,徐辉,等.基于流体动力断弧的高速电弧放电加工[J].电加工与模具, 2012(5):50-54.
- [37]蒋毅.微小孔电火花加工过程控制系统的研究[D].上海:上海交通大学, 2011.
- [38]王海蛟.短电弧高速铣削加工工艺研究[D].济南:山东大学, 2015.
- [39]王用贤,韩福柱.直流运动电弧铣削加工研究[C]//第13届全国特种加工学术会议论文集.哈尔滨:哈尔滨工业大学出版社,2009.
- [40]陈小康,周建平,许燕,等.短电弧铣削加工圆柱电极边角损耗研究[J].现代制造工程, 2019(10):77-81.
- [41]许佩霞.电火花加工极间电场数值的模拟与试验[J].机械制造与自动化, 2008(6):155-158.
- [42]刘宇,赵福令,王元刚,等.集肤效应对微细电火花加工的影响[J].大连理工大学学报, 2010, 50(3):362-367.
- [43]王元刚,王虎,吴蒙华,等.微细电火花加工圆柱电极的损耗研究[J].现代制造工程, 2013(2):9-13+24.
- [44]雍耀维,郭常宁,杨磊.趋肤效应和磁场对电加工特性影响研究[J].机械设计与制造, 2015(2):4-7.
- [45] PEI J Y, ZHANG L N, DU J Y, et al. A model of tool wear in electrical discharge machining process based on electromagnetic theory[J]. International Journal of Machine Tools and Manufacture, 2017, 117:31-41.
- [46]彭子龙,钱雪立,张艺耀,等.微细电火花放电通道自身磁场仿真研究[J].电加工与模具, 2016(5):14-18.
- [47]尹青峰,王宝瑞,李建原.电火花加工电极间隙电场分布研究[J].机械, 2013, 40(1):27-31.
- [48]郭建梅,何虎,姜浩,等.电火花加工放电通道建立过程的电磁场耦合模型[J].电加工与模具, 2022(6):8-11+40.
- [49]于丽丽,刘永红,纪仁杰,等.非导电工程陶瓷电火花加工放电通道模拟[J].系统仿真学报, 2009, 21(1):286-288.
- [50] LASAGNI A, SOLDERA F, MUCKLICH F. FEM simulation of local heating and melting during electrical discharge plasma impact[J]. Modelling and Simulation in Materials Science and Engineering, 2004, 12(5):835-844.
- [51] MARAFONA J, CHOUSAL J A G. A finite element model of EDM based on the joule effect[J]. International Journal of Machine Tools and Manufacture, 2006, 46(6):595-602.
- [52] ASSARZADEH S, GHOREISHI M. Electro-thermal-based finite element simulation and experimental validation of material removal in static gap single-spark die-sinking electro-discharge machining process[J]. Proceedings of the Institution of Mechanical Engineers Part B:Journal of Engineering Manufacture, 2017, 231(1):28-47.
- [53] WANG K, ZHANG Q H, ZHU G, et al. Research on the energy distribution of micro EDM by utilization of electro-thermal model[J]. The International Journal of Advanced Manufacturing Technology, 2017, 93:4179-4186.
- [54] LIU J F, GUO Y B. Residual stress modeling in electric discharge machining(EDM)by incorporating massive random discharges[J].Procedia CIRP, 2016, 45:299-302.
- [55] KOENIG W, WEILL R, WERTHEIM R, et al. The flow fields in the working gap with electro discharge machining[J]. Annals of the CIRP, 1977, 25(1):71-76.
- [56] HARUKA T, KUNIEDA M. Relation between debris concentration and discharge gap length in EDM process[J]. International Journal of Electrical Machining, 2007, 41(8):156-162.
- [57] TAKEUCHI H, KUNIEDA M. Effects of volume fraction of bubbles in discharge gap on machining phenomena of EDM[C]//Proceedings of the 15th International Symposium on Electromachining. Pittsburgh:ISEM XV, 2007.
- [58] PONTELANDOLFO P, HAAS P, PEREZ R. Particle hydrodynamics of the electrical discharge machining process. Part 2:die sinking process[J]. Procedia CIRP, 2013, 6(38):47-52.
- [59] WANG J, HAN F Z. Simulation model of debris and bubble movement in consecutive-pulse discharge of electrical discharge machining[J]. International Journal of Machine Tools and Manufacture, 2014, 77:56-65.
- [60]刘宇,刘创业,马付建,等.基于内冲液的电火花小孔加工间隙流场仿真研究[J].航空制造技术, 2020, 63(4):36-42.
- [61]谷萌,李丽,孙浩.单脉冲电火花放电对镍基高温合金Inconel 718热力学影响研究[C]//第15届全国特种加工学术会议.南京:中国机械工程学会, 2013.
- [62] TAO J, NI J, SHIH A J. Modeling of the anode crater formation in electrical discharge machining[J]. Journal of Manufacturing Science and Engineering, 2012, 134(1):011002.
- [63] TANG J J, YANG X D. A novel thermo-hydraulic coupling model to investigate the crater formation in electrical discharge machining[J]. Journal of Physics D:Applied Physics, 2017, 50(36):365301.
- [64]唐佳静.基于热流耦合分析的电火花加工材料蚀除及表面质量研究[D].哈尔滨:哈尔滨工业大学, 2018.
- [65]李晓惠,韦东波,杨晓冬.电火花加工放电通道的多物理场耦合仿真研究[J].电加工与模具, 2019(3):27-31+74.
- [66] SHIMADA S, TANAKA H, MOHRI N, et al. Molecular dynamics analysis of self-sharpening phenomenon of thin electrode in single discharge[J]. Journal of Materials Processing Technology, 2004, 149:358-362.
- [67] WANG Z L, CUI J Z. Study of molecular dynamics simulation of deposition in air in micro EDM[C]//First International Conference on Integration and Commercialization of Micro and Nanosystems. Sanya:ASME, 2007.
- [68]冯慧慧,杨晓冬.微细电火花加工放电凹坑形成及其表面变质层特性的分子动力学模拟研究[J].电加工与模具, 2015(3):16-20.
- [69] DIJCK F V. Physico-mathematical analysis of the electro discharge machining process[D]. Leuven:Katholieke Universiteit Leuven,1973.
- [70] SNOEYS R, DIJCK F V. Investigations of EDM operations by means of thermomathematical models[J]. Annals of the CIRP,1971, 20:35-36.
- [71] SNOEYS R, DIJCK F V. Plasma channel diameter growth affects stock removal[J]. Annals of the CIRP, 1972, 21(1):39-40.
- [72] YANG X D, GUO J W, CHEN X F, et al. Molecular dynamics simulation of the material removal mechanism in micro-EDM[J].Precision Engineering, 2011, 35(1):51-57.
- [73]岳晓明.电火花加工材料蚀除机理及表面变质层形成研究[D].哈尔滨:哈尔滨工业大学, 2018.
- [74]米乐.电熔爆等离子体电弧的模拟仿真[D].太原:中北大学, 2016.
- [75] XU H, GU L, ZHAO W S, et al. Influence of flushing holes on the machining performance of blasting erosion arc machining[J].Proceedings of the Institution of Mechanical Engineers Part B:Journal of Engineering Manufacture, 2017, 231(11):1949-1960.
- [76] ZHANG F W, GU L, HU J, et al. A new thermal model considering TIE of the expanding spark for anode erosion process of EDM in water[J]. The International Journal of Advanced Manufacturing Technology, 2016, 82:573-582.
- [77] ZHANG Y Z, LIU Y H, SHEN Y, et al. A novel method of determining energy distribution and plasma diameter of EDM[J].International Journal of Heat&Mass Transfer, 2014, 75:425-432.
- [78] ZHANG R, ZHANG Y Z, LIU Y H, et al. Energy distribution and material removal of electric arc machining(EAM)[J]. Journal of Materials Processing Technology, 2017, 242:110-116.
- [79] LI X Z, ZHOU J P, WANG K D, et al. Temperature field simulation of the molten pool in SEAM[J]. International Journal of Advanced Manufacturing Technology, 2018, 94:1513-1523.
- [80]仇未星,周建平,许燕,等. Ti-6Al-4V短电弧铣削加工热源的有限元分析[J].机床与液压, 2023, 51(1):147-151.
- [81]季玉,周建平,汪兵兵,等.基于温度场的C/Si C复合材料短电弧放电加工等效热源研究[J].制造技术与机床, 2023(4):9-14.
- [82]王翔. GH4169短电弧铣削加工表面粗糙度预测模型与实验研究[D].乌鲁木齐:新疆大学, 2021.