CN107649755B - High-speed arc discharge grinding composite processing method - Google Patents
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Abstract
A high-speed electric arc discharge grinding combined machining method adopts a tool electrode with an electrode side surface capable of forming electric arc discharge and a grinding layer at the bottom of the electrode to combine the high-speed electric arc discharge machining and the grinding machining. The invention realizes the high-efficiency, low-cost and high-precision processing of various conductive materials in one device.
Description
Technical Field
The invention relates to a conductive material, in particular to a high-speed arc discharge grinding composite processing method of the conductive material.
Background
High-speed arc discharge machining is a new machining method which is specially proposed for the urgent need of efficient and low-cost machining of difficult-to-cut materials. The principle is that the workpiece material is rapidly melted or even gasified by utilizing the high temperature of arc plasma generated by discharge, and the eroded material is rapidly rushed out of a gap by matching with a high-speed flow field between a tool electrode and the workpiece. However, since the arc has an extremely high energy density, the energy per discharge pulse is also large for the purpose of achieving high efficiency, which results in large pits on the surface of the workpiece after arc discharge machining, resulting in a rough surface. The surface after the electric discharge machining is cooled by the working fluid, a recast layer is easily formed on the surface to increase the hardness, and the surface is rough, so that the subsequent finish machining can be negatively affected, and the service life of the cutter is shortened. If the processing method combining the arc discharge processing and the grinding processing can be adopted in the processing process, the processing with high efficiency and low cost can be realized, and the problems of rough surface and the like after the arc discharge processing can be effectively solved. Specifically, a specially designed tool electrode (the side surface can form discharge, and the bottom is provided with a grinding layer) is adopted to realize synchronous arc discharge machining and grinding machining; the side surface of the electrode and the workpiece form high-energy arc discharge thermal etching to remove workpiece materials, remove most of the materials and form a rough machining surface, and meanwhile, the grinding layer at the bottom of the electrode is used for grinding the surface of the workpiece after arc machining, so that a high-quality surface is finally obtained. Therefore, the high-speed arc discharge grinding combined machining method can realize high-speed arc discharge grinding combined machining and realize the functions of realizing high-efficiency, low-cost and precise machining on one arc discharge machining machine.
In recent years, thanks to the rapid development of arc discharge machining, many researchers have proposed various new methods for etching workpiece materials based on arc discharge, and these methods can effectively solve some problems faced in machining, but these methods also have some disadvantages. In the last century, the Weifang City workshop Wood working machinery shop disclosed its respective anode mechanical cutting device and partial structure in patent CN87212711 and Suzhou electric machine tool research institute Limited in patent CN201644967, respectively. Anodic mechanical cutting machines are generally of the disk type and the belt type. Connecting the workpiece with the anode of a direct current power supply, connecting the cutting electrode with the cathode of the power supply, and spraying conductive electrolyte at the cutting opening. In the cutting process, when the tool is in contact with the front surface of a workpiece, the anode purification film on the workpiece is scratched and removed by the tool (an iron belt) which directly moves at a high speed to form a loop, electric sparks and short electric arc discharge are generated, and the instantaneous local high temperature reaches more than 5000 ℃. However, the machining precision and surface roughness of the anode mechanical cutting technology are poor, the tool electrode is extremely easy to wear, and the anode mechanical cutting technology is only used for cutting blanks or blanking.
Patent CN87106421A discloses a new technology of electric discharge mechanical grinding combined machining method and equipment. The technology is named as electric melting explosion machining, and is a method for realizing electric arc discharge machining by using low voltage and large current. When the device works, the cutter head tool is connected with the negative pole of a power supply, the workpiece is connected with the positive pole of the power supply, and a discharge arc with high energy density is generated between the poles, so that the local part of the surface of the workpiece is rapidly melted and gasified and is rapidly exploded and thrown away. Meanwhile, the tool and the workpiece do relative rotation motion to realize forced mechanical motion arc breaking of the discharge arc, so that efficient and stable arc discharge machining is achieved. In the meantime, patent CN 1061175a discloses a non-contact high-power electric machining technique similar to electric melting explosion, which is called short arc machining, through search of the prior art.
However, a large amount of heat generated by applying a discharge current of several thousands of amperes to a workpiece by electric melting explosion and short arc during machining is difficult to be discharged in time, and the temperature rise of an electrode, the surface of the workpiece and a machine tool part is easily too high, so that the surface structure of the machined workpiece is damaged. Therefore, the surface quality of the workpiece processed by the technology is low, and the technology is not suitable for occasions with high requirements on the surface of the workpiece. Meanwhile, the adopted disc tool electrode and the rotation motion thereof ensure that the method is mainly suitable for processing excircle parts such as rollers and grinding rollers, simple grooving and the like.
The distributed arc electric erosion machining method disclosed in patent CN 1693024a by general electric company is a method for machining by using a distributed arc generated by using the relative motion between the end surface of a hollow tubular electrode and the surface of a workpiece. The method is utilized to mill layer by layer to contour the curved surface, and the high-efficiency material removal rate can be obtained. In patent CN1397399A, suter electromechanical technology limited in suzhou discloses a method for performing high-efficiency milling discharge machining by using rotation of a simple hollow long electrode, and experimental comparison is performed on hollow long electrodes with different length-diameter ratios. The patent CN 1597216a also discloses the use of a hollow long electrode as a main part and other devices as an auxiliary part to efficiently cool and discharge chips during high-speed discharge. However, the above patents are typical arc discharge machining methods, and machining effects similar to those of high-speed arc discharge machining can be achieved by applying arc plasma of large energy density. However, they have only explained the arc discharge machining process and method, and have not performed a further synchronous grinding process on the machined surface after the arc machining to further improve the quality of the machined surface.
Meanwhile, the search of the prior art shows that the electrolytic grinding composite machining is a discharge composite machining method which is widely applied in recent years. The technology is characterized in that an electrolytic machining power supply is added on the basis of a traditional grinding machine tool, machining voltage is loaded between a grinding wheel and a workpiece, and meanwhile, electrolyte sprayed by a grinding layer is matched, so that materials can be removed through grinding of the grinding wheel, and electrolytic machining can be formed between the grinding wheel and the workpiece to remove the materials. However, the technology mainly uses a grinding wheel to grind and remove workpiece materials, and uses an electrolytic machining auxiliary material removal method as an auxiliary material, so that the machined surface is high in quality and the machining precision is good. However, the machining efficiency is low, and the improvement of the machining efficiency is not significant compared with the traditional grinding machining, and is far lower than the arc discharge machining efficiency, so that the machining efficiency is not suitable for the efficient, low-cost and large-allowance removal machining of the difficult-to-cut materials. The technology simultaneously applies grinding processing and electrolytic processing, and the processing efficiency is limited; however, the method provided by the invention firstly adopts the arc discharge to remove the material efficiently, and then adopts the grinding processing in the same process to further improve the quality of the processed surface and improve the processing precision.
The invention provides a high-speed arc discharge machining method, which is a cluster electrode high-speed discharge machining method disclosed in patent CN102091839A by a team member of the subject group, Zhaowangsheng, Gulin and the like. The technology is a typical arc discharge machining method based on a cluster electrode disclosed in patent CN1657208A and used for realizing a hydrodynamic arc breaking mechanism for strengthening the flushing in a plurality of holes. Through recent research, the method has good effects on the efficient, low-cost and large-allowance removal of difficult-to-cut materials, such as the maximum material removal rate of 16000mm when the nickel-based superalloy is processed3The maximum efficiency of processing titanium alloy can reach 21000mm per minute (by adopting 600A current)3The maximum material removal rate of the aluminum-based silicon carbide material in processing can reach 8000mm at min (adopting 600A current)3And/min (adopting 600A current), the machining efficiency is several times or even dozens of times of that of the traditional mechanical cutting machining method. However, although the high-speed arc discharge machining has high efficiency, the surface of the machined workpiece is rough, so that the quality and the machining precision of the machined surface are affected, and further application and popularization of the high-speed arc discharge machining are restricted. Therefore, the method is mainly applied to rough machining of efficient and large-allowance removal of parts at present.
However, in order to implement efficient, low-cost, and high-precision machining of various conductive materials in one device and further expand the application field and range of high-speed arc discharge machining, it is necessary to optimize and further expand research on the existing arc discharge machining method to solve the problem of poor surface quality after machining.
Disclosure of Invention
Aiming at the defects of the existing machining method, the invention provides a high-speed arc discharge grinding combined machining method, which combines high-speed arc discharge machining and grinding machining by adopting a tool electrode with an electrode side surface capable of forming discharge and a grinding layer at the bottom of the electrode, thereby realizing high-efficiency and low-cost machining of a difficult-to-cut material and effectively solving the problem of poor surface quality after machining in arc discharge machining.
The technical scheme adopted by the invention for solving the technical problem is as follows:
a high-speed arc discharge grinding composite processing method is characterized by comprising the following steps:
1) installing a workpiece on a machine tool workbench, installing a tool electrode on a machine tool spindle, and enabling the installation axis of the tool electrode to be superposed with the axis of the machine tool spindle; working medium in the working medium container enters the tool electrode through a flushing liquid inlet on the tool electrode, passes through an internal channel of the tool electrode, reaches a machining area through the side wall and the bottom outlet of the tool electrode, realizes flushing liquid in the electrode during machining, and finally flows back to the working medium container through a worktable of the machine tool to form a working medium loop;
2) respectively connecting a workpiece and a tool electrode with two poles of a machining power supply, forming electric discharge between the side surface of the tool electrode and the workpiece when the workpiece and the tool electrode are machined under the action of the power supply, driving the tool electrode to rotate by a machine tool spindle, feeding to a specified depth along the vertical direction of the surface of the workpiece, and feeding along the tangential direction of the surface of the workpiece, wherein the side surface of the tool electrode always keeps a certain gap with the surface of the workpiece to perform electric discharge and form an electric discharge machining area, and simultaneously the bottom surface of the tool electrode cuts into the surface of the workpiece subjected to electric arc electric discharge machining for a certain depth to further perform grinding machining;
3) according to the shape and the contour of a workpiece to be machined, the tool electrode is driven by a machine tool spindle to move along a machine tool X, Y or a Z axis, meanwhile, the workpiece is arranged on a machine tool workbench, the workbench can rotate along an A axis or a B axis of the machine tool to realize the movement of the workpiece, and the tool electrode and the workpiece are linked to realize the tangential movement of the tool electrode along the surface of the workpiece; after completing one layer of machining, the tool electrode is axially fed a depth, a new layer of machining is started, and the process is repeated until the machining is completed.
The processing power supply is a direct current power supply with the peak current of 1A-1000A, the pulse width of 1 mus-10 ms and the pulse interval of 0-10 ms.
The working medium flows between the tool electrode and the workpiece under the pressure of more than 0.1MPa, and comprises water-based working liquid, mist or gas.
The rotating speed of the tool electrode is 100RPM to 400,000 RPM.
The depth of the feeding layer of the tool electrode along the axial direction is 0.1-3000 mu m.
The bottom end face of the tool electrode is provided with an electrode grinding layer which is fixedly connected with the electrode, so that grinding processing of a to-be-ground area can be realized.
Compared with the prior art, the invention has the beneficial effects that:
the invention relates to a high-speed arc discharge grinding composite processing method, and solves the following problems:
1) the high-speed discharge machining and the grinding machining are effectively combined, and the high-efficiency, low-cost and high-precision machining of various conductive materials is completed on one device;
2) the method can realize the grinding processing of the surface formed by the discharge in a short time after the arc discharge is finished; at this time, since the process of arc discharge etching the workpiece is just finished, the surface temperature of the workpiece remains a part of high temperature during discharge, so that the surface of the workpiece is softened and the grinding process is easily performed.
3) The invention effectively improves the surface quality of the arc discharge machining and further expands the application field and range of the high-speed arc discharge machining.
Drawings
FIG. 1 is a schematic view of a high-speed arc discharge grinding hybrid machining apparatus according to the present invention;
FIG. 2 is a schematic diagram of the high-speed arc discharge grinding composite machining method and an enlarged view of the machining area thereof;
in the figure: 1: discharge power supply, 2: machine tool body, 3: workpiece, 4: tool electrode, 5: workbench, 6: working medium storage tank, 7: machining area, 8: electrode grinding layer, 9: plasma, 10: discharge pit, 11: area to be ground, 12: a working medium.
Detailed Description
The present invention will be further described with reference to the accompanying drawings, but the scope of the present invention should not be limited thereto.
Referring to fig. 1, fig. 1 is a schematic view of a high-speed arc discharge grinding hybrid machining apparatus according to the present invention, and the high-speed arc discharge grinding hybrid machining method according to the present invention includes the following steps:
1) installing a workpiece 3 on a machine tool workbench 5, installing a tool electrode 4 on a machine tool spindle, and enabling the installation axis of the tool electrode to be superposed with the axis of the machine tool spindle; working medium in the working medium container 6 enters the tool electrode through a flushing liquid inlet on the tool electrode 4, passes through an internal channel of the tool electrode, reaches a machining area 7 through the side wall and the bottom outlet of the tool electrode, realizes flushing liquid in the electrode during machining, and finally flows back to the working medium container 6 through the machine tool workbench 5 to form a working medium loop;
2) respectively connecting a workpiece 3 and a tool electrode 4 with two poles of a machining power supply 1, forming electric discharge between the side surface of the tool electrode 4 and the workpiece 3 during electric machining, driving the tool electrode 4 to rotate by a machine tool spindle, feeding to a specified depth along the vertical direction of the surface of the workpiece 3, and feeding along the tangential direction of the surface of the workpiece, wherein the side surface of the tool electrode 4 always keeps a certain gap with the surface of the workpiece 3 to perform electric discharge and form an electric discharge machining area, and simultaneously the bottom surface of the tool electrode 4 cuts into the surface of the workpiece subjected to arc electric discharge machining to a certain depth to further perform grinding machining;
3) according to the shape and the contour of a workpiece 3 to be machined, the tool electrode 4 is driven by a main shaft of the machine tool to move along an X, Y or Z axis of the machine tool, meanwhile, the workbench 5 can rotate along an A axis or a B axis of the machine tool to realize the movement of the workpiece 3, and the tool electrode 4 and the workpiece 3 are linked to realize the tangential movement of the tool electrode along the surface of the workpiece; after completing one layer of machining, the tool electrode 4 is axially fed by one depth, a new layer of machining is started, and the process is repeated until the machining is completed.
Furthermore, the processing power supply is a direct current power supply with the peak current of 1A-1000A, the pulse width of the direct current power supply is 1 mus-10 ms, and the pulse interval is 0-10 ms; the working medium is a working medium flowing between the tool electrode and the workpiece under the pressure of more than 0.1MPa, and can be water-based working liquid, mist or gas; further, the rotation speed of the tool electrode is 100RPM-400,000 RPM; furthermore, the depth of the feeding layer of the tool electrode along the axial direction is 0.1-3000 μm, and the bottom end face of the tool electrode 4 is provided with an electrode grinding layer 8 which is fixedly connected with the tool electrode 4 and can realize the grinding processing of the area 11 to be ground.
Further, as shown in fig. 2, the high-speed arc discharge grinding combined machining method of the present invention combines high-speed arc discharge machining and grinding machining by using a special tool electrode 4 (the side surface of the electrode can form discharge, and the bottom of the electrode has a grinding layer). This technique requires rotation of the tool electrode and assists high speed flushing of the machining area. When the technology is implemented, firstly, arc discharge is formed between the side surface of a tool electrode and a workpiece, the high-temperature plasma 9 formed by the arc discharge in a discharge point area 7 thermally erodes the material of the workpiece 3, meanwhile, a large discharge erosion pit 10 is formed after the arc discharge machining, the surface of the pit is rough and needs to be further ground and finished, and therefore, the pit is called as an area to be ground 11; and then, the grinding layer 8 at the bottom of the tool electrode 4 grinds the area to be ground 11 after the electric arc machining, and the surface of the workpiece is finished, so that the high-surface-quality machining is realized. In the machining process, arc discharge occurs between the outer circular surface of the tool electrode 4 and the workpiece 3, and the arc plasma 9 slides and deflects arc under the combined action of tool rotation and internal flushing liquid, so that the surface is prevented from being burned while materials are removed; the electrode grinding layer 8 also has a liquid flushing effect, can efficiently cool the processing surface, avoids burning caused by excessive surface temperature rise, and can help the grinded and eroded chips to be discharged out of the processing area through a chip discharge groove in the grinding layer.
Best mode for carrying out the invention
The high-speed arc discharge grinding composite processing method of the invention is described according to figures 1 and 2: selecting having 5-axis couplingsA movable numerical control machine tool selects a stainless steel square material as a workpiece material 3, selects a special tool electrode 4 (the side surface of the electrode can form discharge, and the bottom of the electrode is provided with a grinding layer), fixes the workpiece 3 on a machine tool workbench 5, connects the tool electrode 4 to a machine tool spindle, and rotates at the rotating speed of 3000 r/min. Respectively connecting the workpiece 3 and the tool electrode 4 to the positive end and the negative end of the discharge power supply 1, and setting power supply parameters as follows: peak voltage 90V, peak current 500A, pulse width 5000 μ s and pulse interval 3000 μ s. The working fluid medium 12 is selected to be water-based emulsion, and the pressure of the outlet flushed by the working fluid medium is 1.6 MPa. And (4) carrying out high-speed arc discharge grinding combined machining under the process conditions. First, the tool electrode 4 is moved to the outside of the contour of the workpiece 3 near the edge of the workpiece material, and the tool electrode 4 is lowered to a position 2mm below the upper surface of the workpiece 3. When the tool electrode 4 is fed tangentially along the surface of the workpiece 3, the side surface of the tool electrode 4 is first discharged with the workpiece 3, and the arc discharge generates high-temperature plasma 9 to etch away the material of the workpiece 3, forming the surface of the discharge pit 10, which is rough, and the roughness Ra is preliminarily estimated to be measured as high as 16 μm or more, and since this rough machined surface needs to be further ground, this surface area is referred to as a to-be-ground area 11 in this invention. Then, with the transverse feeding of the tool electrode 4, the grinding layer 8 at the bottom of the tool electrode 4 moves to the area 11 to be ground, and grinding processing is carried out to smooth the processing surface so as to improve the surface quality. When the method is used for processing the stainless steel material, the early experimental result preliminarily shows that: the processing efficiency can reach 2000mm3More than min, and the roughness of the processed surface can be expected to be less than Ra3.2, compared with the surface processed by the traditional electric arc, the method has great improvement.
Claims (5)
1. A high-speed arc discharge grinding composite processing method is characterized by comprising the following steps:
1) a workpiece (3) to be machined is arranged on a machine tool workbench (5), a tool electrode (4) is arranged on a main shaft of a machine tool, and the installation axis of the tool electrode (4) is superposed with the axis of the main shaft of the machine tool; working media in the working medium container (6) enter the tool electrode through a flushing liquid inlet on the tool electrode (4), and reach a machining area (7) through an internal channel of the tool electrode and a side wall outlet and a bottom outlet of the tool electrode, so that flushing liquid in the electrode during machining is realized, and finally, the working media flow back to the working medium container (6) through the machine tool workbench (5) to form a working medium loop;
2) respectively connecting a workpiece (3) and a tool electrode (4) with two poles of a processing power supply (1), discharging the side surface of the tool electrode (4) and the workpiece (3) after electrification, generating plasma (9) and corroding workpiece materials to form the surface of a discharge corrosion pit (10), wherein the tool electrode (4) is driven by a machine tool main shaft to rotate, simultaneously, the feed is fed to a specified depth along the vertical direction of the surface of the workpiece (3) and is fed along the tangential direction of the surface of the workpiece, the side surface of the tool electrode (4) keeps a certain gap with the surface of the workpiece (3) all the time to carry out electric discharge and form an electric discharge machining area (7), simultaneously, the bottom surface of the tool electrode (4) is cut into the surface of the workpiece after the arc discharge machining for a certain depth, further grinding the surface of the workpiece through an electrode grinding layer (8) arranged on the bottom surface of the tool electrode (4);
3) according to the shape and the contour of a workpiece (3) to be machined, the tool electrode (4) is driven by a main shaft of a machine tool to move along the X, Y or Z axis of the machine tool, meanwhile, the workbench (5) rotates along the A axis or the B axis of the machine tool to realize the movement of the workpiece (3), and the tool electrode moves tangentially along the surface of the workpiece through the linkage of the tool electrode (4) and the workpiece (3); after completing one layer of machining, the tool electrode (4) is axially advanced by a depth to start a new layer of machining, and the process is repeated until the machining is completed.
2. The high-speed arc discharge grinding hybrid machining method according to claim 1, wherein the machining power supply (1) is a dc power supply having a peak current of 1A to 1000A, a pulse width of 1 μ s to 10ms, and a pulse interval of 0 to 10 ms.
3. The high-speed arc discharge grinding composite machining method according to claim 1, wherein the working medium is a working medium flowing between the tool electrode (4) and the workpiece (3) at a pressure of 0.1MPa or more, and includes a water-based working fluid or mist.
4. The high-speed arc discharge grinding composite machining method according to claim 1, wherein the tool electrode rotation speed is 100RPM to 400,000 RPM.
5. The high-speed arc discharge grinding composite machining method according to claim 1, wherein the depth of the feed layer of the tool electrode in the axial direction is 0.1 μm to 3000 μm.
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| CN108284320B (en) * | 2018-03-07 | 2020-07-17 | 新疆短电弧科技开发有限公司 | Cradle type double-rotary workbench special for short-arc combined machining center |
| CN109759659B (en) * | 2019-01-30 | 2021-06-01 | 上海交通大学 | Efficient coarsening processing system and method for contour surface |
| CN109746534B (en) * | 2019-02-18 | 2021-04-30 | 上海交通大学 | Blade disc part machining system and method based on combination of arc discharge and milling |
| CN110744155B (en) * | 2019-10-23 | 2022-02-22 | 扬州大学 | Efficient electrolytic grinding device and machining method for honeycomb sector |
| CN112475496B (en) * | 2020-11-19 | 2022-10-21 | 首都航天机械有限公司 | Water-based working solution for electric spark machining and electric arc machining and preparation method and application thereof |
| CN114871518A (en) * | 2021-12-15 | 2022-08-09 | 长沙理工大学 | Electric arc additive and electrochemical discharge additive reduction composite manufacturing device and method |
| CN114770231A (en) * | 2022-04-29 | 2022-07-22 | 上海交通大学 | Grinding and high-speed electric spark machining device, machine tool and method combining in-situ grinding and high-speed electric spark machining |
| CN115213503B (en) * | 2022-09-20 | 2023-03-17 | 扬州市职业大学(扬州开放大学) | Wire cutting equipment with grinding process |
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