微细电火花集成加工工件表面重铸层的成形机制和电解去除方法的研究

项目名称： 微细电火花集成加工工件表面重铸层的成形机制和电解去除方法的研究

项目编号： No.51505400

项目类型： 青年科学基金项目

立项/批准年度： 2016

项目学科： 机械、仪表工业

项目作者： 褚旭阳

作者单位： 厦门大学

项目金额： 20万元

中文摘要： 微细电火花集成加工工件内部含有残余热应力，工件表面重铸层中包含有气泡和裂纹等缺陷，将影响其在微机械等领域的应用。项目针对微细电火花集成加工工件表面重铸层成形机制不明确、加工一致性差、电解蚀除特性研究不足、在线-定量-定向去除困难等问题展开。首先研究微细电火花加工工件表面重铸层成形机制，分析不同工艺方法对重铸层特征形貌和热影响层的影响机制，建立以重铸层形貌特征、厚度和热影响层厚度为目标，适用于集成加工各种工艺方法的重铸层去除余量预测方法。其次，对重铸层在线电解蚀除方法进行研究，分析电解过程中重铸层、热影响层和内部基体的去除原理和过程。最后，利用重铸层预测结果和电解蚀除特性、使用微细电火花在线制作工具、采用合适的进给方式，对复杂微小三维零件上不同结构表面的重铸层进行在线、定向、定量的电解蚀除工艺的研究。通过项目的研究，将建立一套完整的集成电加工工艺方法，解决高表面质量的微小三维零件的制造问题。

中文关键词： 微细电火花加工；重铸层；放电机理；蚀除；微细电解加工

英文摘要： The recast layer on workpiece surface produced by integrated micro-EDM contains cracks and residual thermal stress, which will affect its applications in areas such as micro-mechanical. There are several problems for recast layer that the forming mechanism is not clear, processing consistency is poor, electrolytic erosion characteristics are blurred and removal process is difficult. Therefore, this project will firstly study the forming mechanism of recast layer in micro-EDM. The influence mechanism to the recast layer and residual stress layer by different micro-EDM methods will be studied. The predictive model for the surface morphology and thickness of both recast layer and residual stress layer will be built which is applied for each micro-EDM method. Secondly, the online ECM method to processing the recast layer will be studied, and the removal mechanism of recast layer, residual stress layer and workpiece will be analyzed respectively in the process. Finally, the study of ECM to the recast layer which is covered on the surface of small complex three-dimensional parts will be conducted on the multifunctional micro-EDM machine tool, at the same time, the prediction results of recast layer, ECM erosion characteristics, micro-EDM online authoring tool and the appropriate feed methods are also considered in this processing. Eventually, a complete set of integrated method of micro-EDM and micro-ECM will be established to fabricate the small three-dimensional parts with high quality surface.

英文关键词： micro-EDM;recast layer;discharge mechanism;erosion;micro-ECM