TC4钛合金电火花线切割拐角误差控制技术研究

Research on Corner Error Control Technology of TC4 Titanium Alloy Wire EDM

电火花线切割在加工拐角时,会产生电极丝滞后弯曲等现象,导致拐角加工精度降低。针对这一问题,采用正交试验法对TC4钛合金进行拐角加工,研究脉宽、放电间隙、功率放大管数以及变频值参数对直线圆弧拐角的影响,并对试验结果进行极差分析以及方差分析,寻找最优参数组合,确定各参数对试验结果的影响程度,实现对拐角加工误差的有效控制。试验结果表明,对于直线-圆弧拐角误差,放电间隙B和功率放大管数C影响显著,其最优参数组合:脉宽为20μs、放电间隙为12μm、放电通道为6个以及变频值50Hz,拐角误差为183.27μm。对于圆弧-直线拐角误差,脉宽A、放电间隙B和变频值D因素影响显著,其最优参数组合:脉宽为28μs、放电间隙为8μm、放电通道为4个以及变频值50Hz时,拐角误差为224.12μm。

When WEDM processes the corners,the electrode wire will bent,which will reduce the machining accuracy of the corners.In order to solve this problem,the influence on the linear circular corner ofthe pulse width,discharge gap,the number of power tubeand variable frequency value was analyzed with the method of orthogonal experiment carried out to the corner machining of TC4 titanium alloy.The extreme difference analysis andvariance analysis on the test results were implemented to find the optimal parameter combination,confirm the influence degree of various parameters on the test resultsand achieve the effective control of corner machining errors.The experimental results showed that the discharge gap(B)and the number of power amplifier tubes(C)had significant effects on the corner error of the line-arc,with the optimal parameter combination of 20μs pulse width,12μm discharge gap,6 discharge channelswith 50Hz frequency conversion and 183.27μm corner error.As for thearc-straight line corner error,pulse width(A),discharge gap(B)and frequency conversion value(D)had a significant influenceWiththe optimal parameter combination of 28μs pulse width,8μm discharge gap,4discharge channelswith 50Hz frequency conversion value and 224.12μm corner error.