仪器制造技术-自己做的特种加工1.ppt

特种加工技术现代加工技术Non-Traditional Manufacturing ProcessesModern Machining Processes 特种加工是直接利用电、热、声、光及化学能等能量形式进行的加工。如：超声波加工、电化学加工、电火花加工以及它们的复合加工。 特种加工的特点 1.加工时工具不与工件直接接触，加工工具不受工件材料的物理机械性能的限制，因而工具的硬度可低于工件材料的硬度。 2.加工能量大，且易于控制、转换。能源利用效率高。 3.便于实现特殊形状零件的加工及微细加工。 4.机床运动简单、便于自动化和制造高精度机床。 5.特种加工的概念是相对的,发展的。电火花线切割→快速成形。另一特点是微纳米制造中在使用这些技术和发展这些技术。书P149页总结4条 Why Are Advanced Process Required High hardness and the strength of the material 硬，难加工材料 Work-piece too flexible工件是软材料 Material brittle 脆材料 Complex shape形状复杂 Surface finish and dimensional tolerances Temperature rise during conventional processes 切削温度对加工影响无法控制和满足加工要求时 Includes: Chemical Machining (CM) 化学加工，就是腐蚀 Electrochemical Machining (ECM) 电解加工 Electro-Discharge Machining (EDM) and Wire EDM 电火花 电火花线切割 Electron-beam Machining 电子束加工 Laser cutting 激光加工 Ultrasonic Machining (USM) 超声波 Water-Jet and Abrasive Water-Jet Machining 水切割 It can be classified as: Mechanical Energy Processes机械能Ultrasonic Machining， water-jet cutting Thermal Energy Processes热能 EDM Wire EDM, Electron Beam, Laser Beam Chemical Milling ,Photochemical Machining化学能 What has been changed by it? 改变了我们设计机械零部件时的思路； 改变了传统的加工工艺路线； 改变了衡量零件结构工艺性的标准； Electrical-Discharge MachiningEDM电火花加工 Fig : Schematic illustration of the electrical-discharge machining process. This is one of the most widely used machining processes, particularly for die-sinking operations. 加工模具好 How to remove material? Why Graphite etc can be used as Electrode? 钨、钼、石墨等材料熔点、沸点高，因此很难蚀除。铜的熔点、沸点虽然较低但导热性好，所以也很难电腐蚀，因此这些材料可用做工具电极材料。考虑加工难度和加工成本，生产中多采用铜和石墨等材料作为工具电极。 Craft Paramter 工艺参数 The tool (electrode) usually acts as a cathode and is immersed in a dielectric fluid. DC voltage (~300V) is applied in modulated pulses (200-500K Hz). The gap is 0.01-0.2mm between tool and workpiece The sparks produce 5000-10000?C temperature. Current density is 104-107A/mm2 Pulse delay time 10-4-10-7 second The tool is progressively lowered as the workpiece erodes.怎么实现跟随? Material removal rate is typically 30