放电位置随机分布的电火花线切割加工仿真模型

doi:10.3901/JME.2019.17.200

机械工程学报 ›› 2019, Vol. 55 ›› Issue (17): 200-206.doi: 10.3901/JME.2019.17.200

• 制造工艺与装备 • 上一篇

放电位置随机分布的电火花线切割加工仿真模型

白宇飞, 王振龙, 赵朝夕, 王玉魁

哈尔滨工业大学机电工程学院哈尔滨 150001

收稿日期:2018-08-11 修回日期:2019-04-27 发布日期:2020-01-07
通讯作者: 王振龙(通信作者),男,1963年出生,博士,教授,博士研究生导师。主要研究方向为特种加工技术、微细加工技术、机电控制技术、加工过程的智能化技术。E-mail:wangzl@hit.edu.cn
作者简介:白宇飞,男,1993年出生。主要研究方向为电火花加工技术。E-mail:baiyf_hit@163.com

Simulation Model of WEDM with Random Distribution of Discharge Position

BAI Yufei, WANG Zhenlong, ZHAO Zhaoxi, WANG Yukui

School of Mechatronics Engineering, Harbin Institute of Technology, Harbin 150001

Received:2018-08-11 Revised:2019-04-27 Published:2020-01-07

摘要/Abstract

摘要： 在电火花线切割单脉冲放电过程仿真的基础上，基于有限元软件ANSYS提出了一种放电位置随机分布的电火花线切割加工温度场仿真模型。在仿真过程中，放电位置随机分布，并引入"生死单元技术"去除高温蚀除的单元，得到了线切割连续脉冲放电加工过程的表面效果。然后利用温度场仿真结果计算不同放电参数下的材料去除率，并基于脉冲利用率和电极丝换向时间进行修正，发现修正后材料去除率仿真结果与实际加工结果之间误差小于10%，验证了电火花线切割加工连续脉冲随机放电的仿真模型的准确性。其中，电火花线切割加工过程的脉冲利用率、电极丝换向时间是导致仿真结果出现偏差的主要因素。为了分析实际加工过程的脉冲利用率，搭建了脉冲利用率检测装置，对不同伺服条件下的脉冲利用率进行了统计。

关键词: 电火花线切割, 连续脉冲随机放电, 材料去除率, 温度场, 脉冲利用率

Abstract: Based on the simulation of single-pulse discharge process of WEDM, a simulation model of temperature field of WEDM with random distribution of discharge position is proposed based on finite element software ANSYS. In the simulation process, the discharge position is randomly distributed, and the "life and death unit technique" is introduced to obtain the erosion effect of the continuous discharge process of the WEDM. Then the temperature field's simulation results are used and the material removal rate under different discharge parameters is calculated. Based on the pulse utilization rate and the wire reversal time, it is found that the error between the modified material removal rate simulation result and the actual machining result is less than 10%, and the accuracy of the continuous pulse random discharge simulation model of WEDM is verified. Among them, the pulse utilization rate and the wire reversal time of the WEDM process are the main factors leading to the deviation of the simulation results. In order to analyze the pulse utilization rate of the actual machining process, a pulse utilization rate's detection device was built to calculate the pulse utilization rate under different servo conditions.

Key words: WEDM, continuous pulse random discharge process, material removal rate, temperature field distribution, pulse utilization rate

中图分类号:

TG156

白宇飞, 王振龙, 赵朝夕, 王玉魁. 放电位置随机分布的电火花线切割加工仿真模型[J]. 机械工程学报, 2019, 55(17): 200-206.

BAI Yufei, WANG Zhenlong, ZHAO Zhaoxi, WANG Yukui. Simulation Model of WEDM with Random Distribution of Discharge Position[J]. Journal of Mechanical Engineering, 2019, 55(17): 200-206.

参考文献

[1] 赵万生. 先进电火花加工技术[M]. 北京:国防工业出版社,2003. ZHAO Wansheng. Advanced electrical discharge machining technology[M]. Beijing:National Defense Industry Press,2003.
[2] 程国柱,刘志东,田宗军,等. 基于ANSYS电火花线切割加工的温度场分析[J]. 电加工与模具,2008(6):24-26. CHENG Guozhu,LIU Zhidong,TIAN Zongjun,et al. Temperature field analysis based on ANSYS in WEDM[J]. Electromachining & Mould,2008(6):24-26.
[3] 谷萌,李丽,王飞飞,等. 镍基合金IN718电火花线切割单脉冲放电温度场分析[J]. 机械设计与制造,2013(9):151-154. GU Meng,LI Li,WANG Feifei,et al. The temperature field analysis of nickel-base alloy IN718 in WEDM single pulse discharge[J]. Machinery Design & Manufacture,2013(9):151-154.
[4] 张云卿. 基于ANSYS的气中线切割加工温度场及蚀除量仿真[D]. 哈尔滨:哈尔滨理工大学,2015. Zhang Yunqing. Simulation of temperature field and erosion amount of WEDM in gas based on ANSYS[D]. Harbin:Harbin University of Science and Technology,2015.
[5] KURIACHEN B,VARGHESE A,SOMASHEKHAR K P,et al. Three-dimensional numerical simulation of microelectric discharge machining of Ti-6Al-4V[J]. The International Journal of Advanced Manufacturing Technology,2015,79(1-4):147-160.
[6] TALLA G,SAHOO D K,GANGOPADHYAY S,et al. Modeling and multi-objective optimization of powder mixed electric discharge machining process of aluminum/alumina metal matrix composite[J]. Engineering Science and Technology,an International Journal,2015,18(3):369-373.
[7] SHANTANU S S,PANDE S. Development of a thermo-physical model for multi-spark wire EDM process[J]. Procedia Manufacturing,2016,5:205-219.
[8] SOMASHEKHAR K P,PANDA S,MATHEW J,et al. Numerical simulation of micro-EDM model with multi-spark[J]. The International Journal of Advanced Manufacturing Technology,2015,76(1-4):83-90.
[9] LIM H J,DOMBLESKY J P,KIM N,et al. FE simulation of material removal and surface properties for EDM during single and multiple spark occurrences[C]//Tech. Connect World Innovation Conference,2015.
[10] OKADA A,UNO Y,NAKAZAWA M,et al. Evaluations of spark distribution and wire vibration in wire EDM by high-speed observation[J]. CIRP Annals-Manufacturing Technology,2010,59(1):231-234.
[11] JOSHI S N,PANDE S S. Thermo-physical modeling of die-sinking EDM process[J]. Journal of Manufacturing Processes,2010,12(1):45-56.
[12] SINGH H. Experimental study of distribution of energy during EDM process for utilization in thermal models[J]. International Journal of Heat and Mass Transfer,2012,55(19):5053-5064.
[13] IKAI T,HASHIGUSHI K. Heat input for crater formation in EDM[C]//Proceedings of International Symposium for Electro Machining-ISEM XI,EPFL,Lausanne,Switzerland. 1995:163-170.
[14] 张建华,孟艳华,刘承帅,等. 超声振动辅助气中放电加工温度场模拟[J]. 工具技术,2004,38(9):69-71. ZHANG Jianhua,MENG Yanhua,LIU Chengshuai,et al. Simulation of temperature field of ultrasonic vibration aided electrical discharge machining in gas[J]. Tool Engineering,2004,38(9):69-71.
[15] 谭真,郭广文. 工程合金热物性[M]. 北京:冶金工业出版社,1994. TAN Zhen,GUO Guangwen. Thermophisical properties of engineering alloy[M]. Beijing:Metallurgical Industry Press,1994.

放电位置随机分布的电火花线切割加工仿真模型

Simulation Model of WEDM with Random Distribution of Discharge Position

PDF

可视化

摘要/Abstract

引用本文

使用本文

参考文献

相关文章 15

编辑推荐

Metrics

本文评价

[1]	岳彩旭, 都建标, 刘献礼, LIANG S Y, WANG Lihui, 高海宁, 李恒帅. 考虑时变性热强度和时变性热量分配比的铣刀前刀面瞬态温度场建模研究[J]. 机械工程学报, 2019, 55(9): 206-216.
[2]	何玉辉, 徐彦斌, 唐进元, 赵波. 磨削弧区高阶函数热源分布模型研究[J]. 机械工程学报, 2019, 55(7): 199-206.
[3]	魏东, 石友安, 胡斌, 寿比南, 桂业伟. 电磁超声法测量结构内部温度场的试验研究[J]. 机械工程学报, 2019, 55(6): 93-99.
[4]	阮智玮,阚超豪,王垒. 盆式绝缘子温度场仿真分析 ^*[J]. 电气工程学报, 2019, 14(3): 41-46.
[5]	陈蕾,孙跃,方金龙,鲍晓华. 永磁轮毂电机过载状态下的温升计算[J]. 电气工程学报, 2019, 14(1): 9-14.
[6]	王大朋,马田. 两种转子结构的永磁无刷直流高速电机转子受力及损耗温度场分析[J]. 电气工程学报, 2018, 13(8): 12-17.
[7]	李静,许鹏娟,杨光,冯宇宁,付思. 盐密对污秽复合绝缘子电场与温度场的影响研究[J]. 电气工程学报, 2018, 13(7): 23-30.
[8]	张金煜, 虞大联, 林鹏. 基于旋转热源法和均布热源法的列车踏面制动温度场分析[J]. 机械工程学报, 2018, 54(6): 93-101.
[9]	陈明,陈永军,李力森. 变频柜在风电机组塔底工作的散热研究[J]. 电气工程学报, 2018, 13(5): 33-39.
[10]	侯春光,唐帅,高有华,韩颖,曹云东. 电动汽车直流充电桩散热系统优化分析[J]. 电气工程学报, 2018, 13(5): 8-13.
[11]	李洋, 马立峰, 姜正义, 黄志权, 林金宝, 姬亚峰. 通过流固耦合加热的轧辊温度场分析[J]. 机械工程学报, 2018, 54(24): 51-60.
[12]	杨敏, 李长河, 张彦彬, 贾东洲, 张仙朋, 李润泽. 神经外科颅骨磨削温度场预测新模型[J]. 机械工程学报, 2018, 54(23): 215-222.
[13]	丁树业, 仵程程, 刘建峰, 李忠雨. 全封闭扇冷式感应电动机通风结构方案[J]. 机械工程学报, 2018, 54(22): 160-167.
[14]	刘一搏, 张鸿名, 孙清洁, 李军兆, 冯吉才. 磁场作用下铝/钢CMT焊接温度场及熔池流动行为[J]. 机械工程学报, 2018, 54(2): 48-54.
[15]	杨敏, 李长河, 张彦彬, 王要刚, 李本凯, 李润泽. 骨外科纳米粒子射流喷雾式微磨削温度场理论分析及试验[J]. 机械工程学报, 2018, 54(18): 194-203.