水溶性电火花电解复合加工工作液的制备及其对割缝效果的影响

孙永兴; 曲馨; 王引真; 冯涛; 赵凯磊

doi:10.13433/j.cnki.1003-8728.20180083

水溶性电火花电解复合加工工作液的制备及其对割缝效果的影响

doi: 10.13433/j.cnki.1003-8728.20180083

中国石油大学(华东) 机电工程学院, 山东青岛 266580

详细信息

作者简介:
孙永兴(1964-), 教授, 硕士生导师, 研究方向为机械设计及专用焊接设备研究, sunyx80@163.com

中图分类号: TG661
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出版历程
- 收稿日期: 2018-01-10
- 刊出日期: 2018-12-05

Preparation of Water-soluble Working Fluid and Influence on Slotting Performance for Electrical Discharge Machining and Electrochemical Machining

College of Mechanical and Electronic Engineering, China University of Petroleum(East China), Shandong Qingdao 266580, China

摘要

摘要: 割缝筛管是机械防砂的重要设备，试验采用电火花电解复合加工的新方法对割缝筛管进行加工。针对传统的水基工作液加工效率低，而常用的煤油闪点低，安全性差等缺点，试验研制了一种新型电火花电解复合加工水溶性工作液。采用正交试验确定最佳基础工作液，并添加爆破剂蔗糖、电解质等，研究对复合加工的影响规律，并与机油加工的效果进行对比。结果表明，在温度为30℃的条件下，纯水、聚乙二醇400及三乙醇胺的比例为m（水）:m（聚）:m（三）=11:11:3时，基础工作液10%（质量分数）稀释液性能最优。在其基础上加入35g蔗糖，1g NaNO₃和0.25gNaCl可以得到最佳的加工效果。与机油加工工作液相比表面粗糙度减小，加工效率降低且缝宽有所增加，清洁性与安全性提高。
- 电火花电解复合加工 /
- 水溶性 /
- 蔗糖 /
- 加工效率 /
- 缝宽
Abstract: Slotted screen is an important equipment for mechanical sand, a new method via electrical discharge machining (EDM) combined electrochemical machining (ECM) is used to manufacture the screen. Aiming at the shortcomings of traditional water based working fluids, such as low processing efficiency, low kerosene flash point and poor safety, a new water-soluble working fluid for EDM combined machining was developed. The best basic working fluid was determined by orthogonal test, and sucrose, electrolyte and so on were added in the compound processing, and the difference between the compound processing and the oil processing was compared. The results showed that at a temperature of 30℃ the ratio of pure water, polyethylene glycol 400 and triethanolamine was of 11:11:3, and the performance of the basic working fluid with a mass fraction of 10% was the best. The best processing effect can be obtained by adding 35 g sucrose on the basis of 1g NaNO₃ and 0.25gNaCl. Compared with the working fluid of oil processing, the surface roughness was reduced, the processing efficiency was reduced and the width of the seam was increased, and the cleanness and safety were improved.
- EDM combined ECM /
- water-soluble /
- sucrose /
- processing efficiency /
- slit width

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图 1 蔗糖含量对复合加工的影响

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图 2 电解质含量对复合加工的影响

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表 1 基础成分正交试验设计

水平	温度/℃	纯水/g	聚乙二醇400/g	三乙醇胺/g
1	30	280	385	35
2	45	385	245	70
3	60	490	105	105

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表 2 以加工效率为评价指标正交试验结果

试验号	A 温度/℃	B 纯水/g	C 聚乙二醇400/g	D 三乙醇胺/g	加工效率/(mm·s^-1)
1	1	1	1	1	6.16×10^-3
2	1	2	2	2	6.26×10^-3
3	1	3	3	3	4.95×10^-3
4	2	1	2	3	5.70×10^-3
5	2	2	3	1	4.16×10^-3
6	2	3	1	2	4.56×10^-3
7	3	1	3	2	3.22×10^-3
8	3	2	1	3	5.19×10^-3
9	3	3	2	1	4.68×10^-3
k₁	5.79	5.02	5.64	5.00
k₂	5.14	5.20	5.54	5.01
k₃	4.36	5.06	4.11	5.28
极差R	1.43	0.18	1.53	0.28
较优水平	A₁	B₂	C₁	D₃
因子主次	2	4	1	3

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表 3 以缝宽为评价指标正交试验结果

试验号	A 温度/℃	B 纯水/g	C 聚乙二醇400/g	D 三乙醇胺/g	缝宽/mm
1	1	1	1	1	0.42
2	1	2	2	2	0.44
3	1	3	3	3	0.45
4	2	1	2	3	0.46
5	2	2	3	1	0.46
6	2	3	1	2	0.45
7	3	1	3	2	0.45
8	3	2	1	3	0.46
9	3	3	2	1	0.44
k₁	0.437	0.443	0.443	0.440
k₂	0.457	0.453	0.447	0.447
k₃	0.450	0.447	0.453	0.457
极差R	0.02	0.01	0.01	0.017
较优水平	A₁	B₁	C₁	D₁
因子主次	1	3	3	2

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表 4 蔗糖含量对复合加工的影响

蔗糖/g	加工效率/ (mm·s^-1)	缝宽/mm	表面粗糙度/ μm
0	6.59×10^-3	0.42	2.876
17.5	7.16×10^-3	0.42	2.931
35	8.41×10^-3	0.40	2.943
52.5	6.29×10^-3	0.39	3.066
70	6.57×10^-3	0.39	2.417

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表 5 电解质含量对复合加工的影响

电解质含量/g	电导率/ (μs·cm^-1)	加工效率/ (mm·s^-1)	缝宽/ mm	表面粗糙度/μm
0	87.6	6.78×10^-3	0.39	2.943
1+0.25	285	7.01×10^-3	0.39	3.025
2+0.5	508	4.18×10^-3	0.40	3.712
3+0.75	730	2.82×10^-3	0.40	3.606
4+1	904	2.57×10^-3	0.39	2.195

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表 6 水溶性工作液最终配方

成分	含量/%
聚乙二醇400	5.5
三乙醇胺	1.5
蔗糖	0.5
平平加A20	0.2
十二烷基苯磺酸钠	0.3
NaCl	0.003 57
NaNO₃	0.014 3
消泡剂	0.1
防锈剂	0.171
纯水	余量

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表 7 机油与水溶性工作液割缝效果对比

工作液	加工效率/ (mm·s^-1)	缝宽/mm	表面粗糙度/ μm
水溶性工作液	8.57×10^-3	0.39	2.970
机油	9.92×10^-3	0.34	3.217

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