异质箔叠层圆盘电极外缘面微沟槽电火花变损耗成形及旋转加工磨粒效应

The project proposes a variational wear electric discharge forming method of microgrooves on working surface of laminated disc electrode with different material foils. The disc electrodes consisting of different material foils with the same diameters are used to machine microgrooves by micro-EDM. Due to different tool wear rate (TWR) of the different foils, the disc electrode working surfaces wear gradually and form stable microgrooves. Following this, the disc electrode is not required to shape profiles during the micro-EDM process. The laminated disc electrodes exhibit a strong anti-interference property and can machine multiple microgrooves at the same time, resulting in an outstanding efficiency. Therefore, this method is especially suitable for machining microstructures on the surfaces of difficult-to-cut/grind materials, large stroke workpieces and even non-planar workpieces...For revealing the variational wear forming mechanism of the microgrooves on the working surfaces of laminated disc electrodes, with the same machining depth, the project will not only focus on the complete development process of microgroove cross-section profile on the disc electrode working surface from occurrence, gradual development to final stabilization during electric discharge forming process in sequence, but also establish a relation model between the component of the disc electrodes and the cross-section profile of microgrooves. In addition, the disc electrodes electroplated diamond grits near the edge zone on both undersurfaces will be investigated about its effect on the renewal of working fluids and machining gaps during micro-EDM to master the abrasive effect which significantly improves the machining accuracy and efficiency because of the special gap flow field.

提出一种异质箔叠层圆盘电极外缘面微沟槽电火花变损耗成形方法，将初始外径相同的异质圆盘箔组合成叠层圆盘电极来电火花加工微沟槽，由于不同材质的圆盘箔具有不同的损耗速率，电极工作面逐渐损耗形成稳定的微沟槽，之后电极不必修形，叠层圆盘电极抗干扰能力强，可成组加工微沟槽，加工效率大大提高。本方法特别适合于难切削/磨削材料、大行程、甚至曲面上微结构的加工。.聚焦研究在相同加工深度下，叠层圆盘电极逐轮成形时电极工作面微沟槽断面轮廓从产生、逐渐发展、到最终趋于稳定的完整过程，建立叠层圆盘电极箔材构成与微沟槽断面轮廓形状的关系模型，从而揭示叠层圆盘电极工作面微沟槽电火花变损耗成形机理；聚焦研究在圆盘箔两底面接近外缘区域电镀金刚石磨粒后，对旋转电火花加工时工作液更新及加工间隙的影响规律，从而掌握电镀磨粒的叠层圆盘电极旋转电火花加工形成特殊间隙流场、显著提升加工精度与效率的磨粒效应。

本项目提出一种异质箔叠层圆盘电极外缘面微沟槽电火花变损耗成形方法，利用不同材料的工具电极具有不同的电火花损耗速率这一特性，将电极损耗这一不利因素转化为制备微沟槽结构的有益工艺。具有稳定工作面的叠层电极可用于相同微结构的持续加工，期间电极不必修形。叠层圆盘电极抗干扰能力强，可成组加工微沟槽，加工效率大大提高。.项目研究Cu/Sn界面热扩散梯度效应及CuSn合金电极电火花加工特性，实现了微沟槽中二次微结构的加工。详细研究了叠层圆盘电极逐轮成形时电极工作面微沟槽断面轮廓从产生、逐渐发展、到最终趋于稳定的完整过程，并建立了叠层圆盘电极箔材构成与微沟槽断面轮廓形状的数学模型和仿真模型，揭示了叠层圆盘电极工作面微沟槽电火花变损耗成形机理，进而实现了准确预测加工过程中微沟槽轮廓的演变；对比研究了有/无电镀金刚石磨粒的圆盘电极对微沟槽加工的影响，掌握了电镀磨粒的叠层圆盘电极旋转电火花加工形成特殊间隙流场、显著提升加工精度与效率的磨粒效应。.此外，基于本项目的主要思想，对加工方法进行了拓展，探索了齿状圆盘电极电火花电解旋转复合加工以及异质箔叠层电极倒置式往复电火花变损耗成形制备微沟槽结构。