负压电火花加工深小孔实验研究

Experimental study on negative pressure assisted electrical discharge machining of deep small holes

  • 摘要: 在电火花加工深径比小孔时,随着深度增加,排屑困难导致加工稳定性下降,限制了深径比提升。为此,本研究提出一种负压电火花加工方法,通过负压环境促进极间气泡形成,结合管电极内冲液共同强化排屑。实验表明,在相同加工参数下,加工至700 s时,负压电火花加工小孔深径比较常压条件下提升30.01%。通过高速摄影观测发现,负压环境下极间空化气泡增多、易汇聚并且快速逸出。通过对孔壁壁面进行表征,发现负压电火花加工的孔壁更光滑,有效减少侧壁放电现象。该方法通过改善极间流场与排屑能力,为突破深小孔加工的深径比极限提供了新途径。

     

    Abstract: In the electrical discharge machining (EDM) of small holes with a high aspect ratio, as the depth increases, debris removal becomes difficult, leading to decreased machining stability and limiting further improvement in the aspect ratio. To address this, a negative pressure assisted electrical discharge machining (NP-EDM) method is proposed in this study. By promoting the formation of inter-electrode bubbles under a negative-pressure environment and combining it with internal flushing through a tube electrode, debris removal is enhanced. The experiment showed that, under the same machining parameters, when machining for 700 s, the aspect ratio of small holes produced by NP-EDM increased by 30.01% compared to that under atmospheric pressure conditions. High-speed photography revealed that under negative pressure, the number of cavitation bubbles in the gap increases, and they tend to coalesce and escape rapidly. Characterization of the hole walls revealed that NP-EDM produces smoother hole walls and suppresses sidewall discharge. This method improves the inter-electrode flow field and debris removal capability, providing a new approach to breaking through the aspect ratio limit in deep-small-hole EDM.

     

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