电火花加工蚀除过程动态仿真

Dynamic Simulation of Material Removal Process in EDM Process

在电火花单脉冲放电过程仿真的基础上,建立了电火花连续脉冲放电过程的三维热物理模型,利用有限元软件ANSYS模拟了连续脉冲放电过程的温度场分布,得到了连续脉冲放电过程不同时刻温度场分布和材料的动态蚀除过程,并根据脉冲放电的温度场和蚀除凹坑体积,分析了脉冲放电过程的残留温度分布和蚀除凹坑对后续脉冲放电过程的温度场分布和蚀除凹坑体积的影响规律。在仿真过程中,根据数值模拟极间电场强度和分析小孔加工初始时刻放电凹坑分布情况,确定了连续放电仿真模型放电位置的随机选择原则。并通过实验初步验证了材料仿真去除率,为预测材料去除率提供了理论基础。

In the paper, the three-dimensional thermal physical model of the continuous pulse dis- charge in EDM process has been developed on the base of the single pulse electrical discharge process simulation. Temperature field simulation and dynamic simulation of the material removal process has been carried out using ANSYS software and the previous pulse discharge process influence on the sub- sequent pulse discharge process is discussed in terms of temperature field distribution and the volume of craters. Finally, prediction of the material removal rate is also addressed, and its comparison with ex- perimental measurements shows a good agreement, which provides a theoretical basis to predict materi- al removal rate in EDM process.