CN116851852A - Conjugated swing type precise material reduction electric machining technical method - Google Patents
Conjugated swing type precise material reduction electric machining technical method Download PDFInfo
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- CN116851852A CN116851852A CN202310768142.1A CN202310768142A CN116851852A CN 116851852 A CN116851852 A CN 116851852A CN 202310768142 A CN202310768142 A CN 202310768142A CN 116851852 A CN116851852 A CN 116851852A
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- 238000003754 machining Methods 0.000 title claims abstract description 124
- 239000000463 material Substances 0.000 title claims abstract description 86
- 238000000034 method Methods 0.000 title claims abstract description 70
- 230000009467 reduction Effects 0.000 title claims abstract description 58
- 230000033001 locomotion Effects 0.000 claims abstract description 43
- 238000012545 processing Methods 0.000 claims abstract description 38
- 230000008569 process Effects 0.000 claims description 18
- 238000003672 processing method Methods 0.000 claims description 12
- 239000002131 composite material Substances 0.000 claims description 6
- 238000010892 electric spark Methods 0.000 claims description 6
- 239000007788 liquid Substances 0.000 claims description 5
- 229910000838 Al alloy Inorganic materials 0.000 claims description 2
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims description 2
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims description 2
- 229910001080 W alloy Inorganic materials 0.000 claims description 2
- 229910052802 copper Inorganic materials 0.000 claims description 2
- 239000010949 copper Substances 0.000 claims description 2
- 229910002804 graphite Inorganic materials 0.000 claims description 2
- 239000010439 graphite Substances 0.000 claims description 2
- AHADSRNLHOHMQK-UHFFFAOYSA-N methylidenecopper Chemical compound [Cu].[C] AHADSRNLHOHMQK-UHFFFAOYSA-N 0.000 claims description 2
- 239000010935 stainless steel Substances 0.000 claims description 2
- 229910001220 stainless steel Inorganic materials 0.000 claims description 2
- 238000005516 engineering process Methods 0.000 claims 1
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- 238000004519 manufacturing process Methods 0.000 description 5
- 238000004364 calculation method Methods 0.000 description 4
- 239000012224 working solution Substances 0.000 description 4
- 238000004458 analytical method Methods 0.000 description 2
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- 230000001052 transient effect Effects 0.000 description 2
- FFBHFFJDDLITSX-UHFFFAOYSA-N benzyl N-[2-hydroxy-4-(3-oxomorpholin-4-yl)phenyl]carbamate Chemical compound OC1=C(NC(=O)OCC2=CC=CC=C2)C=CC(=C1)N1CCOCC1=O FFBHFFJDDLITSX-UHFFFAOYSA-N 0.000 description 1
- 230000000903 blocking effect Effects 0.000 description 1
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23H—WORKING OF METAL BY THE ACTION OF A HIGH CONCENTRATION OF ELECTRIC CURRENT ON A WORKPIECE USING AN ELECTRODE WHICH TAKES THE PLACE OF A TOOL; SUCH WORKING COMBINED WITH OTHER FORMS OF WORKING OF METAL
- B23H1/00—Electrical discharge machining, i.e. removing metal with a series of rapidly recurring electrical discharges between an electrode and a workpiece in the presence of a fluid dielectric
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23H—WORKING OF METAL BY THE ACTION OF A HIGH CONCENTRATION OF ELECTRIC CURRENT ON A WORKPIECE USING AN ELECTRODE WHICH TAKES THE PLACE OF A TOOL; SUCH WORKING COMBINED WITH OTHER FORMS OF WORKING OF METAL
- B23H3/00—Electrochemical machining, i.e. removing metal by passing current between an electrode and a workpiece in the presence of an electrolyte
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23H—WORKING OF METAL BY THE ACTION OF A HIGH CONCENTRATION OF ELECTRIC CURRENT ON A WORKPIECE USING AN ELECTRODE WHICH TAKES THE PLACE OF A TOOL; SUCH WORKING COMBINED WITH OTHER FORMS OF WORKING OF METAL
- B23H5/00—Combined machining
- B23H5/02—Electrical discharge machining combined with electrochemical machining
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23H—WORKING OF METAL BY THE ACTION OF A HIGH CONCENTRATION OF ELECTRIC CURRENT ON A WORKPIECE USING AN ELECTRODE WHICH TAKES THE PLACE OF A TOOL; SUCH WORKING COMBINED WITH OTHER FORMS OF WORKING OF METAL
- B23H5/00—Combined machining
- B23H5/04—Electrical discharge machining combined with mechanical working
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23H—WORKING OF METAL BY THE ACTION OF A HIGH CONCENTRATION OF ELECTRIC CURRENT ON A WORKPIECE USING AN ELECTRODE WHICH TAKES THE PLACE OF A TOOL; SUCH WORKING COMBINED WITH OTHER FORMS OF WORKING OF METAL
- B23H5/00—Combined machining
- B23H5/06—Electrochemical machining combined with mechanical working, e.g. grinding or honing
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Abstract
The invention relates to a conjugated back swing type precise material reduction electric machining technical method, and belongs to the technical field of electric machining. The method is characterized in that in the material reduction electro-machining process, a certain fixed angle position on a workpiece always keeps a corresponding superposition rule with one or a plurality of fixed angle positions on a tool electrode. The workpiece and the tool electrode do reciprocating back-swing motion around the respective axes, and meanwhile, the tool electrode does continuous feeding motion relative to the workpiece; or the tool electrode makes a swinging motion and a reciprocating linear motion, and the workpiece makes a reciprocating swinging motion. The invention can reduce the processing idle stroke and the space of a motion mechanism of a workpiece containing arc-segment difficult-to-process material, and the integral immersion processing is matched with conjugate backswing motion to improve the chip removal and exhaust conditions of a processing interelectrode gap, so as to obtain a stable and uniform interelectrode gap state, improve the processing precision and the surface integrity of the workpiece.
Description
Technical Field
The invention relates to a back swing type precise material reduction electric machining technical method, and belongs to the technical field of electric machining (Electrical Machining).
Background
The processing method of the workpiece with the arc-containing sector complex concave and convex surface difficult to process materials, in particular to the processing method of the workpiece with the arc-containing sector with larger radius, is mainly realized by the processing method of the workpiece with the arc-containing sector complex concave and convex surface difficult to process materials. Processing methods are classified into two main categories, namely machining methods and reduced material electrical processing methods, depending on the type of energy.
The existing machining method is a method for removing workpiece materials by means of contact between a cutter and the workpiece by using energy in the forms of mechanical energy and thermal energy. According to the method, a multi-axis linkage machine tool is matched with a special tool for machining complex curved surfaces to move according to track planning, and whether finish machining forming is finished by a numerical control grinding machine is determined according to the machining precision requirement of a workpiece. (see patent 1, "a five-axis vertical turning and milling combined machining method for an aero-engine case", application number CN108262591A, applicant Li Bin, yuan Wenyang and the like; see patent 2, "a curved surface machining tool path planning method with cutting force fluctuation as constraint", grant number CN0106125666B, inventor's Ma Wei, gao Yuanyuan and the like). The existing machining method has the problems of long preparation time for complex programming calculation, large cutter loss, high cost, obvious influence of force and heat, residual tensile stress and excessive plastic deformation on the surface of a workpiece, and needs to install auxiliary processes such as heat treatment and the like.
The material-reducing electric machining method is a special machining method for removing workpiece materials by utilizing energy in the form of electric energy, heat energy and chemical energy. The method belongs to non-contact processing, can process any conductive material, and is suitable for precision processing of various cavity surfaces. The machining method suitable for the workpiece containing the difficult-to-machine material with the complex concave and convex surfaces is electric spark machining and electrolytic machining.
For electric spark machining of a workpiece containing a complex concave-convex surface difficult-to-machine material, the existing method is to control relative movement of a tool electrode and the workpiece in a numerical control mode to realize forming, but the machining precision is affected due to the fact that electrode loss exists in the tool electrode, and tool electrode loss compensation is needed.
For the electrolytic machining of workpieces containing complex concave and convex surfaces and difficult to machine materials, the existing methods mainly comprise three categories, namely a 'blocking' electrolytic machining method, a rotary scanning type photographic electrolytic machining method and a rotary printing electrolytic machining method. (see patent 1, "method of electrolytic machining of complex casing surface", application number CN101733491a, applicant Xu, zhu Haina, etc., see article 1, "development and application of photographic electrolytic machining technique", authors Li Gongying, zhang Mingqi, etc., aeronautical manufacturing technique, 2014, 23 rd phase; see patent 2, "metal photographic electrolytic machining process", application number CN1073219a, applicant Liu Gufu; see patent 3, "method and system of electrolytic printing of complex concave-convex surface", grant number CN102179579a, inventor Zhu Di, zhu Zengwei, etc., see patent 4, "double rotational speed printing electrolytic system of concave-convex array structure of revolution body", application number 202011336134.2, applicant Zhu Zengwei, wang Dengyong, etc.). Among the above electrolytic machining methods, the spin-printing electrolytic method has the best precision and surface integrity of machining the casing, and can realize the integral forming of the workpiece.
However, in the existing material reduction electro-machining method, the tool electrode and the workpiece are rotated in a whole circle during machining, and the device is difficult to realize for synchronous or double-angle rotation of the workpiece with a larger diameter. The corresponding circumference angle range is smaller, so that the idle angle in the whole rotation process is large, namely the effective machining travel range is small in occupied ratio, and the overall machining efficiency is low. In addition, as the radius of the arc segment of the workpiece increases, from an equipment perspective: the corresponding slewing mechanism also becomes larger, so that the problems of space loss, operation difficulty, cost increase and the like of the machine equipment are caused. From a machining tool perspective: the diameter of the tool electrode may also be increased, increasing the difficulty of manufacturing the tool electrode.
From the viewpoints of improving the processing efficiency, the processing quality and the surface integrity, the processing method suitable for workpieces of difficult-to-process materials with complex concave and convex surfaces of arc sectors is lacking at present, and particularly, the precise material reduction electric processing method for workpieces with larger arc sector radiuses is lacking. Therefore, there is an urgent need for a reduced-material electric machining method for such workpieces, which has a small machining idle stroke, high machining efficiency, low electrode design and manufacturing and trimming difficulties, and more uniform and stable machining gap distribution.
Disclosure of Invention
The invention aims to:
the invention aims at solving the problems that the processing efficiency is low and the equipment volume is large because the processing time and space travel of the workpiece is many times longer than the effective working travel when the prior art is adopted to process the workpiece with complex concave and convex surfaces containing arc segments and difficult to process, particularly the workpiece with larger arc segment radius. The conjugate pendulum type precise material reduction electro-machining method based on the fact that the tool electrode and the workpiece do reciprocating pendulum motion around respective axes respectively and simultaneously do continuous feeding motion, or the tool electrode does pendulum motion and reciprocating linear motion, and the workpiece does reciprocating pendulum motion is provided, so that the stroke is reduced and the machining gap state is improved during electro-machining, and efficient precise forming of the workpiece with the arc-containing sector complex concave and convex surface difficult to machine is facilitated.
The technical scheme is as follows:
the conjugated swing type precise material reduction electro-machining technical method is suitable for forming a workpiece of a material difficult to machine with a complex concave surface and a convex surface containing arc segments, and is characterized in that: the first shaft and the second shaft are positioned in the same plane in the space and intersect to form a certain fixed angle; the surface to be processed of the workpiece is an arc sector-shaped surface, and the circumference occupation angle of the arc sector-shaped surface is small; the tool electrode is in a revolving body structure; the workpiece is arranged on the first shaft, and the tool electrode is arranged on the second shaft; the workpiece and the tool electrode adopt a liquid supply mode of being completely immersed in the working liquid; in the material reduction electro-machining process, a certain fixed angle position on a workpiece always keeps corresponding superposition rules with a certain fixed angle position or a plurality of fixed angle positions on a tool electrode: one implementation is that the tool electrode reciprocates back around the second axis at an equiangular velocity while the workpiece reciprocates back around the first axis at an equiangular velocity; another implementation mode is that the tool electrode makes a rotary swing motion and a reciprocating linear motion around the second shaft at an equiangular speed, and the workpiece makes a reciprocating back swing motion around the first shaft at an equiangular speed; the ratio K of the swing angular speed of the tool electrode to the swing angular speed of the workpiece is constant, and the value can be adjusted according to the processing requirement; the distance between the workpiece and the tool electrode can be continuously adjusted, so that radial feeding machining movement is realized; when the workpiece and the tool electrode do backswing motion, no relative axial motion exists between the workpiece and the tool electrode; in the process of electro-machining conjugate surfaces such as threads or gears, before converting an electro-machining standard, a tool electrode firstly withdraws from a workpiece, and moves an integral multiple value of the screw pitch or tooth thickness corresponding to the thickness of the workpiece in the axial direction to compensate the loss of the tool electrode, and then the characteristics are repeated to continue machining; the arc sector-shaped surface of the workpiece (3) is etched and processed by the appearance surface of the tool electrode (4) by utilizing the principle of material reduction electro-machining through the motion of the tool electrode and the workpiece according to the angle phase superposition backswing rule.
In the material reduction electro-machining process, the included angle e between the first shaft (1) and the second shaft (2) can be any value between 0 and 90 degrees. In the material reduction electro-machining process, the ratio K of the swinging angular velocity of the tool electrode (4) to the swinging angular velocity of the workpiece (3) is equal to the ratio of the swinging angle of the workpiece (3) to the swinging angle of the tool electrode (4), and when conjugate surfaces such as threads, gears and the like are machined, the ratio K of the swinging angular velocity of the tool electrode (4) to the swinging angular velocity of the workpiece (3) is n orn is a positive integer. On the same device, a single-specification tool electrode (4) is used, and the precise material reduction electro-machining of the workpiece with multiple specifications and complex concave and convex surfaces with arc sectors can be realized by adjusting the ratio K of the swinging angular speed of the tool electrode (4) to the swinging angular speed of the workpiece (3). In the process of reducing the material and machining the concave surface of the workpiece, the swing angular velocity direction of the tool electrode (4) at any time is the same as the swing angular velocity direction of the workpiece (3), and in the process of reducing the material and machining the convex surface of the workpiece, the swing angular velocity direction of the tool electrode (4) at any time is opposite to the swing angular velocity direction of the workpiece (3). In the material reduction electro-machining process, the position of the central axis of the workpiece (3) is kept unchanged, so that the tool electrode (4) performs radial continuous feeding machining to one side of the workpiece (3). In the process of reducing the material, the axial position of the tool electrode (4) is kept unchanged, so that the workpiece (3) is subjected to radial continuous feeding processing to one side of the tool electrode (4). The surface to be processed of the workpiece (3) is an external surface or an internal surface,the patterns of the tool electrode (4) are all outline surface electrodes, and the outline surface of the tool electrode (4) and the surface to be processed of the workpiece (3) are formed. The material of the tool electrode (4) can be graphite, pure copper, stainless steel, aluminum alloy, tungsten alloy and copper-carbon composite material. The material reduction processing method suitable for the characteristics comprises electric spark processing, electrolytic electric spark composite processing and mechanical processing and electric processing composite processing.
Compared with the prior art, the invention has the following beneficial effects:
1. aiming at a workpiece with a complex concave-convex surface with an arc sector and difficult to process, the invention can realize the material reduction electric processing of the workpiece with the complex concave-convex surface with the arc sector and difficult to process by the conjugate backswing movement between the workpiece and a tool electrode;
2. the invention adopts the appearance surface revolving body tool electrode which is easy to manufacture and ensures the processing precision, thereby reducing the manufacturing and detection difficulties of the tool electrode;
3. the invention realizes the material reduction electric machining of the difficult-to-machine material workpiece with complex concave and convex surfaces of arc-containing sectors of various specifications by using a single-specification revolving body tool electrode on the same device;
4. in the electro-machining process, the working fluid flow disturbance is caused by conjugate backswing movement and feeding movement, so that a long and narrow machining area has sufficient and good chip removal and exhaust space, a high-pressure fluid supply mode in the traditional material reduction electro-machining is eliminated, an electro-machining device is reduced, a good interelectrode fluid supply effect can be achieved by matching with simple immersion type machining, a stable and uniform machining gap is obtained, and the machining precision and the surface integrity of a workpiece-shaped surface are improved;
5. the invention reduces the idle stroke ratio in the traditional material reduction electric processing by conjugate backswing movement, improves the processing efficiency and reduces the space and the equipment volume of the movement mechanism of the material reduction electric processing equipment.
Drawings
FIG. 1 is a schematic diagram of forming a workpiece with a convex arc sector by conjugate swing type precise material reduction and electric machining
FIG. 2 is a schematic diagram of forming a workpiece with concave arc sector surface by conjugate swing type precise material reduction and electric machining
Fig. 3 simulation model of conjugated pendulum type precision material reduction electric machining arc sector convex surface forming embodiment (k=8)
Fig. 4 is a grid division of simulation model flow field analysis of a conjugate swing type precision material reduction electro-machining arc sector convex surface forming embodiment
Fig. 5 is a schematic illustration of a point T in a fluid region of a simulation model of an embodiment of forming a convex surface of an arc segment of a conjugate swing-back type precision material reduction electro-machining 1 Is the position of (2)
FIG. 6 is a schematic illustration of a point T in a fluid region of a simulation model of an embodiment of a conjugate swing type precision subtractive electrical machining arc sector convex surface forming 1 Is a statistical velocity profile of (2)
FIG. 7 illustrates a point T of a fluid region of a simulation model of an embodiment of forming a convex surface of an arc segment of a conjugate swing type precision material reduction electro-machining 1 Is a statistical pressure curve of (2)
FIG. 8 external gear electrode conjugate swing type precise material reduction electro-machining large-pitch diameter external gear block embodiment
Fig. 9 embodiment of external screw electrode conjugate swing type precision material reduction electric processing large diameter internal screw arc fan-shaped screw plate (k=2)
FIG. 10 external radial straight line contour electrode conjugate swing type precise material reduction electro-machining cycloidal tooth-shaped template cutter embodiment
FIG. 11 external tooth bar block electrode conjugate swing type precision material reduction electro-machining involute tooth profile sample plate cutter embodiment
Reference numerals in the figures: 1. the device comprises a first shaft, 2, a second shaft, 3, a workpiece, 4, a tool electrode, 5, a working fluid circulation supply system, 6 and a processing power supply.
Detailed Description
The present invention is further described with reference to the following examples and the accompanying drawings, which are only preferred embodiments of the present invention, and are not intended to limit the scope of the present invention. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present invention are included in the protection scope of the present invention.
Fig. 1 is a schematic diagram showing the formation of a conjugated swing type precision material reduction electric machining arc sector convex surface workpiece. The two electrodes are integrally immersed in the working solution, and the arc sector is outsideThe surface-forming workpiece (3) has an equiangular velocity omega 1 About its own axis O 1 The tool electrode (4) is moved back and forth at another equiangular velocity omega in the opposite direction of rotation 2 Around axis O 2 And do reciprocating back-swing motion. The tool electrode (4) being simultaneously along O 1 O 2 And continuously and radially feeding the workpiece (3) with the arc sector outline surface at the speed v in the connecting line direction. At the beginning P on the tool electrode (4) 21 Point and P on the workpiece (3) 11 The point-to-point electrical machining is performed next to P on the tool electrode (4) 22 Point and P on the workpiece (3) 12 The points correspond. When P is on the tool electrode (4) 23 Point and P on the workpiece (3) 13 Connection O at point contact 1 P 14 Is included angle theta 1 To O 2 P 24 Is included angle theta 2 I.e. after which the tool electrode (4) is rotated by θ 2 Corresponding to the conjugate rotation theta of the workpiece (3) in the process 1 Ensure P on the tool electrode (4) 24 Point and P on the workpiece (3) 14 The points correspond to contacts. Similarly, P on the tool electrode (4) 25 Point and uppermost edge P on workpiece (3) 15 And after the point corresponding contact, the tool electrode (4) and the workpiece (3) change the rotation direction at the same time so as to ensure that each relative point corresponds to the corresponding point for reciprocating swing electric machining (the two-dot chain line position in fig. 1 represents two limit positions of the motion of the workpiece (3)), namely, the relative motion of the tool electrode (4) and the workpiece (3) accords with the motion rule of a pair of conjugates of a certain type. In the electric machining process, the calculation formula of the ratio K of the swinging angular speed of the tool electrode (4) to the swinging angular speed of the workpiece (3) is as follows:
fig. 2 shows a schematic diagram of the formation of a workpiece with a concave arc sector surface by conjugate swing type precision material reduction electric machining. The two electrodes are wholly immersed in the working solution, and similar to the forming principle of the workpiece with the arc sector outline surface of the conjugate pendulum type material reduction electric machining, each point on the tool electrode (4) always keeps the rule of mutual superposition of 1 angle phase point corresponding to the arc internal outline surface of the workpiece (3) to carry out the conjugate pendulum type continuous feeding material reduction electric machining.
Fig. 3 shows a simulation model (k=8) of a conjugate swing type precision material reduction electric machining arc sector convex surface forming embodiment, defining a certain moment, and a whole circle O 2 Last point P 24 ，P 24 O 2 Theta with horizontal center line 2 Point P on arc segment 14 ，P 14 O 1 Theta with horizontal center line 1 This embodiment θ 2 ＝8θ 1 I.e. at this pointWhole circle O with tool electrode appearance surface solid boundary phi 7.13mm 2 Around the centre of a circle O at a speed of 16r/s 2 Swing back and forth, its upper and lower limit swing positions P 21 O 2 And P 25 O 2 With horizontal centre line O 1 O 2 The absolute value of the included angle is 96 deg.. The solid boundary of the workpiece is an arc sector consisting of R24.93mm and R21.29mm (the center radius of the arc sector is R23.11 mm), and the arc sector is along the horizontal center line O 1 O 2 Around the centre of a circle O at a speed of 2r/s 1 Swing back and forth, and the upper and lower extreme swing positions and the horizontal central line O 1 O 2 The absolute value of the included angle is 24 deg.. The machining gap between the tool electrode and the arc segment is defined to be 0.5mm. The above flow field model was built in ANSYS2022R1 Workbench Design Modeler.
The simulation model flow field analysis grid division of the conjugate swing type precise material reduction electric machining arc sector convex surface forming embodiment shown in fig. 4 is guided into an ANSYS2022R1 Workbench Mesh assembly, triangular grids are adopted for grid division, and the boundary of a contact area is encrypted so as to ensure the computational accuracy of fluid dynamics. The final grid division diagram is shown in fig. 4, and the calculation shows that the grid cell indexes of the grid model are all above 0.63, so that the computational fluid dynamics simulation requirement can be met. And (3) importing the divided grid model into ANSYS2022R1 Fluent for solving. The main parameters of the solver are set as follows: the pressure-based transient solver is characterized in that a speed equation is set to be an absolute speed equation, a turbulence equation is a standard k-e double equation, and a standard near-wall surface processing mode is adopted; the fluid phase is deionized water; defining a dynamic grid by using a UDF program; selecting a SIMPLEC algorithm; the transient calculation is performed with a time step number of 2000, a time step number of 0.0005s and a maximum iteration number of 10.
FIG. 5 shows a point T of a fluid region of a simulation model of an embodiment of shaping a convex surface of an arc segment of a conjugated pendulum-type precision material reduction electro-machining 1 Is positioned at the midpoint of the machining gap. Midpoint T in the fluid region is measured by an ANSYS2022R1 Workbench post-processing assembly 1 (as in fig. 4) velocity and pressure profiles over time.
FIG. 6 shows a point T of a fluid region of a simulation model of an embodiment of shaping a convex surface of an arc segment of a conjugated pendulum-type precision material reduction electro-machining 1 When T is 1 When the point is positioned at the minimum gap between the electrodes in 1 cycle period, the extreme value speed is arranged at the point, and the lifting amplitude of the speed is obvious relative to other moments.
FIG. 7 shows a point T of a simulated fluid region of a conjugate swing type precision subtractive electro-machining arc sector convex surface forming embodiment 1 The statistical pressure curve at this point tends to plateau. By analyzing the two curves of fig. 6 and 7, it can be known that the machining interelectrode gap has a better flow field state by the conjugate backswing movement between the tool electrode and the workpiece, and the chip removal and exhaust states of the interelectrode gap can be improved, thereby being beneficial to improving the machining efficiency and the machining quality of the reduced-material electric machining.
FIG. 8 illustrates an embodiment of an external gear electrode conjugate swing type precision reduced material electro-machining large pitch diameter external gear block. The two electrodes are wholly immersed in the working solution, the external gear electrode (4) and the gear block (3) made of materials difficult to process meet the condition of conjugate backswing movement, the reciprocating swing angular velocity of the external gear electrode (4) is equal to the reciprocating swing angular velocity (K=1) of the gear block (3) of the workpiece, and meanwhile, the external gear electrode (4) carries out continuous radial feeding processing on the workpiece to obtain the external gear block (3). By increasing the angular velocity ratio K, the small-diameter external gear electrode which is easy to achieve high dimensional accuracy and shape and position accuracy can be used for processing the large-pitch-diameter arc external gear block and the internal gear block by a similar conjugate pendulum type precise material reduction electric processing method.
Fig. 9 shows an embodiment of an external thread electrode conjugate swing type precision material reduction electro-machining large-diameter internal thread arc sector thread rolling plate. The whole two electrodes are immersed in the working solution, the reciprocating swing angular velocity of the single-head external thread electrode is 2 times (K=2) of the reciprocating swing angular velocity value of the large-diameter workpiece, the external thread electrode does feeding motion to the workpiece along the radial direction besides reciprocating swing, and the large-diameter double-head internal thread arc sector thread rolling plate is obtained through a conjugate pendulum type material reduction electric machining method. The large-diameter multi-start thread male thread block and the large-diameter multi-start thread female thread block can be processed in a similar way.
Fig. 10 shows an embodiment of an outer radial straight profile electrode precision subtractive machining cycloidal tooth template blade. The two electrodes are integrally immersed in the working fluid, and the cycloidal tooth-shaped template knife profile on the workpiece (3) is formed by utilizing a pair of radial linear profile backswing motions on the tool electrode (4) and matching with the reciprocating backswing motions and the continuous feeding motions of the workpiece (3). Compared with the method for machining the sample plate knife point by point mechanically, the method for machining the sample plate knife line by using the conjugate swing type precise material reduction electric machining method has the advantages of smooth transition of the sample plate knife line surface, higher dimensional accuracy and more convenient machining.
Figure 11 shows an embodiment of an external spline block electrode precision subtractive machining involute tooth template blade. The two electrodes are wholly immersed in the working liquid, and the rack block tool electrode (4) is at a speed v 2 The reciprocating linear motion is regarded as a special case that the radius of the reciprocating backswing is infinite. The workpiece (3) is reciprocated back and forth while being continuously fed relative to the tool electrode (4). In the final position of processing, the distance between the pitch diameter line of the rack block tool electrode (4) and the backswing axis of the workpiece (3) is equal to the pitch radius of the virtual gear where the involute tooth profile of the template knife is located. And a very accurate cycloid tooth-shaped template knife is obtained by processing by using a linear contour electrode with easy control of processing precision.
Claims (10)
1. The conjugated swing type precise material reduction electric machining technology method is suitable for forming and machining a workpiece of a material difficult to machine with a complex concave surface and a convex surface containing arc segments, and is characterized by comprising the following steps of:
the first shaft (1) and the second shaft (2) are positioned in the same plane in the space and intersect to form a certain fixed angle e;
the surface to be processed of the workpiece (3) is an arc sector-shaped surface, and the circumference occupation angle of the arc sector-shaped surface is small;
the tool electrode (4) is a revolving body structure;
the workpiece (3) is arranged on the first shaft (1), and the tool electrode (4) is arranged on the second shaft (2);
the workpiece (3) and the tool electrode (4) adopt a liquid supply mode of being completely immersed in the working liquid;
in the material reduction electro-machining process, a certain fixed angle position on the workpiece (3) always keeps corresponding superposition rules with a certain fixed angle position or a plurality of fixed angle positions on the tool electrode (4):
one implementation is that the tool electrode (4) is reciprocated back around the second axis (2) at an equiangular speed, while the workpiece (3) is reciprocated back around the first axis (1) at an equiangular speed;
another implementation way is that the tool electrode (4) makes a rotary swing motion and a reciprocating linear motion around the second shaft (2) at an equiangular speed, and the workpiece (3) makes a reciprocating swing motion around the first shaft (1) at an equiangular speed;
the ratio K of the swing angular speed of the tool electrode (4) to the swing angular speed of the workpiece (3) is constant, and the value can be adjusted according to the processing requirement;
the distance between the workpiece (3) and the tool electrode (4) can be continuously adjusted, so that radial feeding machining movement is realized;
when the workpiece (3) and the tool electrode (4) do back swing motion, no relative axial motion exists between the workpiece and the tool electrode;
in the process of reducing the material and electrically machining conjugate surfaces such as threads or gears, before converting an electrical machining standard, the tool electrode (4) firstly withdraws from the workpiece, moves an integral multiple value of the pitch or tooth thickness corresponding to the thickness of the workpiece (3) in the axial direction to compensate the loss of the tool electrode (3), and then repeats the characteristics to continue machining;
the arc sector-shaped surface of the workpiece (3) is etched and processed by the appearance surface of the tool electrode (4) by utilizing the principle of material reduction electro-processing through the motion of the tool electrode (4) and the workpiece (3) according to the angle phase superposition backswing law.
2. The back-swing type material reduction electro-machining technical method according to claim 1, wherein the method comprises the following steps of: in the material reduction electro-machining process, the included angle e between the first shaft (1) and the second shaft (2) can be any value between 0 and 90 degrees.
3. The back-swing type material reduction electro-machining technical method according to claim 1, wherein the method comprises the following steps of: in the material reduction electro-machining process, the ratio K of the swinging angular velocity of the tool electrode (4) to the swinging angular velocity of the workpiece (3) is equal to the ratio of the swinging angle of the workpiece (3) to the swinging angle of the tool electrode (4), and when conjugate surfaces such as threads, gears and the like are machined, the ratio K of the swinging angular velocity of the tool electrode (4) to the swinging angular velocity of the workpiece (3) is n orn is a positive integer.
4. The back-swing type material reduction electro-machining technical method according to claim 1, wherein the method comprises the following steps of: on the same device, a single-specification tool electrode (4) is used, and the precise material reduction electro-machining of the workpiece with multiple specifications and complex concave and convex surfaces with arc sectors can be realized by adjusting the ratio K of the swinging angular speed of the tool electrode (4) to the swinging angular speed of the workpiece (3).
5. The back-swing type material reduction electro-machining technical method according to claim 1, wherein the method comprises the following steps of: in the process of reducing the material and machining the concave surface of the workpiece, the swing angular velocity direction of the tool electrode (4) at any time is the same as the swing angular velocity direction of the workpiece (3), and in the process of reducing the material and machining the convex surface of the workpiece, the swing angular velocity direction of the tool electrode (4) at any time is opposite to the swing angular velocity direction of the workpiece (3).
6. The back-swing type material reduction electro-machining technical method according to claim 1, wherein the method comprises the following steps of: in the material reduction electro-machining process, the position of the central axis of the workpiece (3) is kept unchanged, so that the tool electrode (4) performs radial continuous feeding machining to one side of the workpiece (3).
7. The back-swing type material reduction electro-machining technical method according to claim 1, wherein the method comprises the following steps of: in the process of reducing the material, the axial position of the tool electrode (4) is kept unchanged, so that the workpiece (3) is subjected to radial continuous feeding processing to one side of the tool electrode (4).
8. The back-swing type material reduction electro-machining technical method according to claim 1, wherein the method comprises the following steps of: the surface to be processed of the workpiece (3) is an external surface or an internal surface, the patterns of the tool electrode (4) are external surface electrodes, and the external surface of the tool electrode (4) and the surface to be processed of the workpiece (3) are formed.
9. The back-swing type reduced material electrical processing method according to claim 1, wherein: the material of the tool electrode (4) can be graphite, pure copper, stainless steel, aluminum alloy, tungsten alloy and copper-carbon composite material.
10. The back-swing type reduced material electrical processing method according to claim 1, wherein: the material reduction processing method suitable for the characteristics comprises electric spark processing, electrolytic electric spark composite processing and mechanical processing and electric processing composite processing.
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