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1、 Nanjing University of Aeronautics and Astronautics The Graduate School College of Mechanical and Electrical Engineering The Numerical Simulation and Experimental Research on Material Removal of Spark Erosion in Micro-EDM A Thesis in Mechanical Manufacture and Automation by Feng haidi Advised by Pro
2、fessor Wang Wei Submitted in Partial Fulfillment of the Requirements for the Degree of Master of Engineering January, 2012 承诺书 本人郑重声明：所呈交的学位论文，是本人在导师指导下，独立进行研究工作所取得的成果。尽我所知，除文中已经注明引用的内容外，本学位论文的研究成果不包含任何他人享有著作权的内容。 对本论文所涉及的研究工作做出贡献的其他个人和集体， 均已在文中以明确方式标明。 本人授权南京航空航天大学可以有权保留送交论文的复印件， 允许论文被查阅和借阅,可以将学位论文
3、的全部或部分内容编入有关数据库进行检索，可以采用影印、缩印或其他复制手段保存论文。 (保密的学位论文在解密后适用本承诺书) 作者签名： 日 期： 南京航空航天大学硕士学位论文 I 摘 要 微能放电加工中，材料蚀除规律非常复杂，难以准确预测电极损耗来提高加工精度。由于其微观物理过程很难用现有的实验方法、仪器观察和检测得到，因此，本文采用数值模拟与试验相结合的方法研究电极极性、电极材料及放电能量对微细放电电蚀量的影响规律。 本文首先根据热传导基本理论和微能放电实际情况，建立起微能放电热传播模型，借助ANSYS分析软件，对微细放电两极单脉冲放电温度场进行数值模拟；然后用类似正交试验的方法进行单因素放
4、电试验， 通过测量两极放电蚀坑尺寸计算电蚀量， 并对比仿真结果与试验结果，总结电极极性、电极材料及放电能量对微能放电电蚀量的影响规律。主要工作如下： 1、相同能量下，建立相同模型（20m6m）的碳纤维单丝和铜丝进行单脉冲温度场数值模拟分析及相关试验研究，对比其电极损耗大小，验证碳纤维作为 WEDM 电极丝使用的可行性及优越性。 2、更换电极对，用直径20 m钨丝作放电两极进行单脉冲温度场数值模拟与试验研究，通过改变电参数分析不同放电能量对微能放电两极电蚀量的影响规律。 3、计算两极电蚀量，仿真结果与试验结果对比，总结电极材料和放电能量对电蚀量的影响规律。 本研究具有可行性和现实意义，为微能放电
5、加工极性和材料的选择、放电参数的设定、微能脉冲电源的设计以及工艺参数的改进提供理论指导。 关键词：关键词：微能放电；温度场分布；数值模拟；脉冲能量；电蚀量 微能放电电蚀量的数值模拟与试验研究 II Abstract In micro electrical discharge machining, material removal on discharge is very complex, so its difficult to accurately predict the electrode loss to improve the machining accuracy. Because it
6、is difficult to detect and observe the microscopic physical process by experimental methods and instruments, therefore, in this paper, it has been looked upon the influence of the law of electrode polarity, electrode materials and discharge energy to the material removal of spark erosion, by using n
7、umerical simulation and test method. On the basis of micro electrical discharge process and heat transfer theory, the heat propagation model of electrodes has been primarily established. Then the temperature distribution of anode and cathode with single pulse discharge is simulated respectively by u
8、sing ANSYS. Single pulse discharge experiment is carried out by the orthogonal test method, and the material removal of spark erosion is calculated by measuring the discharge pit size. By comparing the simulation results and experimental results, this paper summarized the influence of law of the ele
9、ctrode polarity, electrode materials and discharge energy to material removal. Following are the main work: 1、In the same discharge energy, a numerical simulation of the discharge temperature field and the experiments of carbon fiber and the commonly used metal wire electrode brass, which are the sa
10、me model of 20m6m, are made. Their wire erosions are contrasted and verified the superiority of carbon fiber as wire electrode of WEDM. 2、The two electrodes are changed and in the different discharge energy, two electrodes of tungsten, having a diameter of 20 m, are used for the numerical simulation
11、 and the experimental research. The influence of discharge energy to material removal is analysed. 3、 By calculating the material removal of spark erosion and comparing the simulation results and experimental results, this paper summarized the influence of law of the electrode polarity, electrode ma
12、terials and discharge energy to material removal. This study has the feasibility and the practical significance and provides theoretcal guidance for selecting the polarity and the materials, setting the discharge parameters, designing the micro pulse power and improving the process parameters of Mic
13、ro-EDM. Keywords: Micro electrical discharge; Temperature field distribution; Numerical simulation; Pulse Energy; Material removal of spark erosion 南京航空航天大学硕士学位论文 III 目 录 第一章 绪论 . 1 1.1 课题来源及研究的目的和意义 . 1 1.2 国内外相关领域的研究现状 . 2 1.2.1 有限元仿真技术在电火花加工中的应用 . 2 1.2.2 微细放电加工电极材料蚀除机理研究 . 4 1.3 本课题主要研究内容 . 6 1.3.1 研究创新点. 7 1.3.2 具体研究内容 . 7 第二章 微能放电物理模型与试验方法的建立 .
