基于ANSYS移动热源电火花线切割温度场仿真研究
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摘要
为了研究移动热源下电火花线切割温度场分布情况,结合热力学知识及放电通道的移动,建立了气中移动热源温度场模型,并推导出移动高斯热源的热力密度公式,确定移动热源下温度场初始条件与边界条件,根据实际加工情况建立仿真模型,利用ANSYS软件模拟了在移动热源下电火花线切割加工过程,得到Cr12MoV工件表面温度场的变化规律以及单个电蚀坑模型,进一步确定电蚀坑分布情况为多级排列,给出理论蚀除量计算公式,为预测工件蚀除率提供了依据。设计单因素实验,结果表明,移动高斯热源下电蚀坑的椭圆形建模是可行的,实际加工条件下电蚀坑形状与仿真结果相符,且由此结论计算的理论蚀除量与实际加工过程中工件的蚀除体积相当接近,验证了建立模型的合理性及仿真研究的可行性。
In order to study the WEDM-HS temperature field distribution under the moving heat source, combined with thermodynamics knowledge and the moving of the discharge channel, the moving heat source temperature field model in the air is established, and heat density formula of moving gauss heat source is deduced. Base on the moving heat source temperature field initial conditions and boundary conditions, simulation model is established according to the actual processing conditions. Edm wire-cut machining the moving heat source is simulated using the ANSYS software. The changing rule of workpiece surface temperature field for Cr12 MoV and single electrical erosion pit model are obtained. The distribution of the electric erosion pit is multi-stage. The theoretical formula for calculating the amount of erosion is presented, which provides a basis for predicting the workpiece removal rate. Single factor experiment is designed, and the results show that elliptic model of the erosion pit under the mobile gauss heat source is feasible. The simulation results of electric erosion pit shape is consistent with and practical processing condition, and the quantity of calculation theory removal is close to that of the actual process, which verify the rationality and feasibility of the model.
In order to study the WEDM-HS temperature field distribution under the moving heat source, combined with thermodynamics knowledge and the moving of the discharge channel, the moving heat source temperature field model in the air is established, and heat density formula of moving gauss heat source is deduced. Base on the moving heat source temperature field initial conditions and boundary conditions, simulation model is established according to the actual processing conditions. Edm wire-cut machining the moving heat source is simulated using the ANSYS software. The changing rule of workpiece surface temperature field for Cr12 MoV and single electrical erosion pit model are obtained. The distribution of the electric erosion pit is multi-stage. The theoretical formula for calculating the amount of erosion is presented, which provides a basis for predicting the workpiece removal rate. Single factor experiment is designed, and the results show that elliptic model of the erosion pit under the mobile gauss heat source is feasible. The simulation results of electric erosion pit shape is consistent with and practical processing condition, and the quantity of calculation theory removal is close to that of the actual process, which verify the rationality and feasibility of the model.
引文
[1]Li Chaojiang,Bai Jicheng,Guo Yongfeng.Research of temperature field simulation on electrode wire wear for WEDM[J].Advanced Materials Research,2011,199:1827-1831.
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[9]郭欢欢.基于移动热源气中电火花线切割加工温度场仿真研究[D].哈尔滨:哈尔滨理工大学,2016.Guo Huanhuan.Simulation study on temperature field of EDM wire cutting in moving heat source gas[D].Harbin:Harbin University of Science and Technology,2016.
[10]杜德盛.高速走丝气中线切割多次切割技术研究[D].哈尔滨:哈尔滨理工大学,2008.Du Desheng.Research on multiple cutting techniques of high-speed wire-cutting in wire-cutting[D].Harbin:Harbin University of Science and Technology,2008.
[11]Masuzawa T,Fujino M,Kobayashi K.Wire electro-discharge grinding for micro-machining[J].Annals of the CIRP.1985,34(1):431-434.
[12]Joshi S N and Pande S S.Thermo-physical modeling of diesinking EDM process[J].Journal of Manufacturing Processes,2010,12(1):45-56.
[13]Shankkar S,Sekh M,Mitra S,et al.A novel method of determination of wire lag for enhanced profile accuracy in WEDM[J].Precision Engineering,2011,35(2):339-347.
[14]Kunieda M,Furuoya S.Improvement of EDM efficiency by supplying oxygen gas into gap[J].Annals of the CIRP,1991,40(1):215-218
[15]Kunieda M,Yoshida M.Electrical discharge machining in gas[J].Annals of the CIRP,1997,46(1):143-146.
[16]刘志东,程国柱,李建军.电火花线切割温度场有限元分析及参数验证[J].中国机械工程,2010,01:38-42.Liu zhidong,Cheng guozhu,Li jianjun.Finite element analysis and parameter validation of EDM wire cutting temperature field[J].China Mechanical Engineering,2010,01:38-42.
[17]李朝将,白基成,郭永丰,等.电火花线切割加工电极丝损耗的温度场仿真研究[J].电加工与模具,2011,S1:35-38+64.Liu Zhidong,Cheng Guozhu,Li Jianjun.Finite element analysis and parameter validation of EDM wire cutting temperature field[J].Electromachining&Mould,,2011,S1:35-38+64.
[2]狄士春,黄瑞宁,迟关心,等.微细电火花线切割加工关键技术[J].机械工程学报,2006,42(01):221-226.Di Shichun,Huang Ruining,Chi Xien,et al.Key technology for fine EDM wire cutting[J].Chinese Journal of Mechanical Engineering,2006,42(01):221-226.
[3]王彤,陈玉全,国枝正典.气中电火花线切割加工技术研究[J].机械工程学报,2003,39(08):76-80.Wang Tong,Chen Yuquan,Guo Zhi zhengdian.Research on EDM wire cutting technology in gas industry[J].Chinese Journal of Mechanical Engineering,2003,39(08):76-80.
[4]李立青,王振龙,赵万生.气体放电加工机理分析[J].哈尔滨工业大学学报,2004,36(3):359-362.Li Liqing,Wang Zhenlong,Zhao Wansheng.Analysis of gas discharge machining mechanism[J].Journal of Harbin Institute of Technology,2004,36(3):359-362.
[5]刘志东.以复合工作液为放电介质的低速走丝电火花线切割可行性研究[J].航空精密制造技术,2007,43(4):39-42.Liu Zhidong.Study on the feasibility of low-speed wire-EDM wire cutting with compound working fluid as discharge medium[J].Aviation Precision Manufacturing Technology,2007,43(4):39-42.
[6]楼乐明.电火花加工计算机仿真研究[D].上海:上海交通大学,2000:33-42.Lou Leming.Computer simulation of EDM[D].Shanghai:Shanghai jiaotong university,2000:33-42.
[7]哲境,王彤.干式介质中单脉冲放电的温度场及流场仿真[C].第14届全国特种加工学术会议论文集,中国机械工程学会特种加工分会,2011.Zhe Jing,Wang Tong.Simulation of temperature field and flow field of single pulse discharge in dry medium[C].Proceedings of the 14th national special machining academic conference,Special machining branch of China mechanical engineering society,2011.
[8]蒋婷.气中电火花线切割加工有限元仿真和实验研究[D].哈尔滨:哈尔滨理工大学,2017.Jiang Ting.Finite element simulation and experimental study of gasmedium EDM wire cutting processing[D].Harbin:Harbin University of Science and Technology,2017.
[9]郭欢欢.基于移动热源气中电火花线切割加工温度场仿真研究[D].哈尔滨:哈尔滨理工大学,2016.Guo Huanhuan.Simulation study on temperature field of EDM wire cutting in moving heat source gas[D].Harbin:Harbin University of Science and Technology,2016.
[10]杜德盛.高速走丝气中线切割多次切割技术研究[D].哈尔滨:哈尔滨理工大学,2008.Du Desheng.Research on multiple cutting techniques of high-speed wire-cutting in wire-cutting[D].Harbin:Harbin University of Science and Technology,2008.
[11]Masuzawa T,Fujino M,Kobayashi K.Wire electro-discharge grinding for micro-machining[J].Annals of the CIRP.1985,34(1):431-434.
[12]Joshi S N and Pande S S.Thermo-physical modeling of diesinking EDM process[J].Journal of Manufacturing Processes,2010,12(1):45-56.
[13]Shankkar S,Sekh M,Mitra S,et al.A novel method of determination of wire lag for enhanced profile accuracy in WEDM[J].Precision Engineering,2011,35(2):339-347.
[14]Kunieda M,Furuoya S.Improvement of EDM efficiency by supplying oxygen gas into gap[J].Annals of the CIRP,1991,40(1):215-218
[15]Kunieda M,Yoshida M.Electrical discharge machining in gas[J].Annals of the CIRP,1997,46(1):143-146.
[16]刘志东,程国柱,李建军.电火花线切割温度场有限元分析及参数验证[J].中国机械工程,2010,01:38-42.Liu zhidong,Cheng guozhu,Li jianjun.Finite element analysis and parameter validation of EDM wire cutting temperature field[J].China Mechanical Engineering,2010,01:38-42.
[17]李朝将,白基成,郭永丰,等.电火花线切割加工电极丝损耗的温度场仿真研究[J].电加工与模具,2011,S1:35-38+64.Liu Zhidong,Cheng Guozhu,Li Jianjun.Finite element analysis and parameter validation of EDM wire cutting temperature field[J].Electromachining&Mould,,2011,S1:35-38+64.