薄壁石墨电极高速加工关键技术分析-analysis of key technologies for high speed machining thin-walled graphite electrodes.docx

内 容 摘 要石墨材料由于自身的诸多优点被广泛应用于电火花加工领域，市场对曲面等薄 壁结构特征石墨电极的需求量已经越来越大。这类零件在加工过程中由于刚度差等 诸多原因，传统的车削、铣削、磨削等加工方式已经无法完成薄壁件的加工，高速 加工技术由于切削力小、可以获得比常规加工更高的表面质量等优点更加有利于薄 壁件的加工。但是在切削力的作用下产生加工变形仍然是石墨薄壁件加工过程中遇 到的难题，切削参数的不合理选取会严重影响到产品的表面质量和加工精度，甚至 导致零件报废。为了研究石墨薄壁件在高速铣削加工过程中切削参数对切削力的影响，以曲面 型石墨薄壁件为例，采用四因素四水平正交试验法结合有限元仿真对其进行铣削试 验；运用有限元仿真手段分析高速铣削过程中加工变形的整体变形特征。通过有限元软件 ANSYS/LS-DYNA 非线性技术对曲面型石墨薄壁件高速铣削 加工过程进行仿真分析。结果表明：切削速度、每齿进给量、轴向切深对切削力没 有太大的影响，径向切深对切削力的影响比较显著，并且随着径向切深的增加切削 力也逐渐增加。在切削力通用公式的基础上，建立了适用于曲面型石墨薄壁件的径 向平均切削力经验公式，并进行了显著性验证。运用 ANSYS 静力分析对曲面型石 墨薄壁件整个加工过程进行模拟分析，结果表明：从工件长度方向上看，每一层的 加工变形趋势是两端大，中间小；从工件高度方向上看，加工变形从上往下逐渐减 小，加工完成后工件整体上呈现出上厚下薄、两端厚中间薄的形状。加工变形严重 影响了加工质量，通过增加刚度可以减小铣削过程中的加工变形。运用有限元软件 对增加刚度的加工工艺进行仿真分析，结果表明：采用大的径向切深更加有利于薄 壁件的加工，在径向切深相同的情况下，与单侧铣削加工方式相比较，阶梯对称铣 削方式对于石墨薄壁件的加工变形有显著效果。在上述研究的基础上，得到了适合曲面型石墨薄壁件高速铣削加工的切削参数 和加工方式，为加工同类型工件提供了理论依据。关键词：石墨薄壁件高速加工切削力变形AbstractGraphite materials are widely used in the electrical discharge machining field because of its sums of advantages, and the demand for the graphite electrode with curved thin-walled structure characteristics has been increasing in the market. However the common processing ways by lathing and milling can not finish the process of thin-walled parts, the high-speed milling can do it well for its small stock removal and acquisition of a higher surface-milling quality. It is still a problem that there will engender machining deformation in the process of the complex curved thin-walled graphite parts, and it has a bad influence on the surface-milling quality and the milling precision, More serious, it may lead to the parts scraping.For the research of the influence that the cutting parameters having on the cutting force in the process of the curved thin-walled graphite parts by the high-speed milling, this article has combined the orthogonal test method(four factors and four levels) and the finite element simulation method to carry out the milling experiment and analyze the whole deformation characteristics in the process of high spee