电火花辅助铣削钛合金多能场建模及调控优化研究

doi:10.3901/JME.2024.09.393

摘要/Abstract

摘要： 钛合金的高质高效切削一直是机械加工领域的难题。虽然有各种热场辅助高效精密加工方法，但缺乏对其力学行为和切削温度等多能场耦合的理论研究，导致难以合理高效地调控优化工艺。针对上述问题，基于热-力耦合的电火花辅助铣削(EDAM)多能场模型进行了调控优化研究，以提高钛合金加工的效率和质量。首先，确定了以电容、转速和电极宽度角为优化变量；然后，建立了热-力耦合的EDAM放电辅助温度和切削力模型；同时，基于响应曲面分析法分析了优化变量对EDAM加工特性的影响，以确定最优参数组合；最终，一系列钛合金EDAM实验验证了理论模型的准确性和优化结果的有效性。研究结果表明，通过理论模型对EDAM加工过程中的多能场的调控优化，EDAM的切削力和表面粗糙度比传统铣削(CM)降低了52.7%和80%。

关键词: 钛合金, 电火花辅助铣削, 多能场, 热-力耦合模型, 调控优化

Abstract: High-quality and efficient cutting of titanium alloys has always been a difficult problem in the field of machining. Although various types of thermal field assisted high-efficiency precision machining methods are applied, there was a lack of theoretical research on the coupling of multi-energy fields such as its mechanical behavior and cutting temperature, which made it difficult to regulate and optimize the process reasonably and efficiently. To address the above problems, A regulation optimization study based on the multi-energy field model for EDAM with thermal-force coupling is carried out, thus to improve the machining efficiency and quality of titanium alloys. Firstly, capacitance, speed and electrode width angle are determined as optimization variables. Then, the models of discharge-assisted temperature and cutting force for EDAM based on thermal-force coupling are developed. Meanwhile, the influence of optimized variables on the processing characteristics of EDAM is analyzed based on response surface methodology (RSM) to determine the optimal parameter combinations. Finally, the accuracy of the theoretical model and the validity of the optimization results are verified by a series of EDAM experiments of titanium alloys. The results show that through the optimization of the theoretical model to regulate the multi-energy field during EDAM machining, the cutting force and surface roughness of EDAM are reduced by 52.7% and 80%, respectively, compared to conventional milling (CM).

Key words: titanium alloys, EDAM, multi-energy field, thermal-force coupling model, regulation optimization

中图分类号:

TG506
TG66

魏荣, 徐默然, 李常平, 李树健, 李鹏南. 电火花辅助铣削钛合金多能场建模及调控优化研究[J]. 机械工程学报, 2024, 60(9): 393-409.

WEI Rong, XU Moran, LI Changping, LI Shujian, LI Pengnan. Modeling of Multi-energy Field and Regulation Optimization for Electric Discharge Assisted Milling (EDAM) of Titanium Alloys[J]. Journal of Mechanical Engineering, 2024, 60(9): 393-409.

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