摘 要
精密电火花加工微小孔技术在航空航天、医疗器械等高端制造领域具有重要应用价值，但传统工艺存在加工效率低、精度难以保证等问题。为此，本研究旨在通过改进电极材料与结构设计、优化放电参数及引入新型辅助技术来提升加工效率和质量。具体而言，采用铜钨合金替代纯铜作为电极材料，其优异的导电性和耐磨性显著提高了加工稳定性；创新性地设计了多级阶梯状电极结构，有效解决了深径比大的微小孔加工难题；基于正交试验法系统优化了脉冲宽度、峰值电流等关键放电参数，建立了适用于不同尺寸微小孔的最佳参数匹配模型；引入超声振动辅助技术，利用空化效应增强蚀除效果并改善排屑条件。实验结果表明，经上述综合改进措施后，微小孔加工效率较传统方法提高约40%，表面粗糙度降低至Ra0.8μm以下，孔径精度控制在±2μm以内。该研究为精密电火花加工微小孔提供了新的思路和技术方案，在提升加工效率的同时确保了高质量加工要求，对推动相关行业技术进步具有重要意义。
关键词：电火花加工 微小孔技术 铜钨合金电极
Abstract
Precision electrical discharge machining (EDM) of micro-holes plays a crucial role in advanced manufacturing fields such as aerospace and medical devices, yet traditional processes suffer from low efficiency and difficulty in ensuring accuracy. To address these issues, this study aims to enhance processing efficiency and quality by improving electrode materials and structural design, optimizing discharge parameters, and introducing novel auxiliary techniques. Specifically, copper-tungsten alloy was used instead of pure copper as the electrode material due to its superior conductivity and wear resistance, significantly improving processing stability. An innovative multi-level stepped electrode structure was designed to effectively solve the challenge of machining deep micro-holes with high aspect ratios. Orthogonal experimental methods were employed to systematically optimize key discharge parameters such as pulse width and peak current, establishing an optimal parameter matching model for micro-holes of various sizes. Ultrasonic vibration assistance was introduced, utilizing cavitation effects to enhance erosion efficiency and improve chip evacuation conditions. Experimental results indicate that after implementing these comprehensive improvements, the efficiency of micro-hole processing increased by approximately 40% compared to traditional methods, surface roughness was reduced to below Ra0.8 μm, and hole diameter accuracy was controlled within ±2 μm. This research provides new insights and technical solutions for precision EDM of micro-holes, enhancing processing efficiency while ensuring high-quality requirements, thereby contributing significantly to technological advancements in relevant industries.
Keyword:Electrical Discharge Machining Micro-Hole Technology Copper Tungsten Alloy Electrode
目 录
1绪论 1
1.1研究背景与意义 1
1.2国内外研究现状 1
1.3本文研究方法 1
2加工参数优化 2
2.1脉冲参数对加工精度的影响 2
2.2电极材料的选择与优化 3
2.3冷却液流量的控制策略 3
3工艺流程改进 4
3.1微小孔加工前处理技术 4
3.2加工过程中的误差补偿 4
3.3后处理工艺的优化方案 5
4效率提升措施 5
4.1快速定位与对中技术 6
4.2自动化加工系统的应用 6
4.3提高加工稳定性的方法 7
结论 7
参考文献 9
致谢 10
精密电火花加工微小孔技术在航空航天、医疗器械等高端制造领域具有重要应用价值，但传统工艺存在加工效率低、精度难以保证等问题。为此，本研究旨在通过改进电极材料与结构设计、优化放电参数及引入新型辅助技术来提升加工效率和质量。具体而言，采用铜钨合金替代纯铜作为电极材料，其优异的导电性和耐磨性显著提高了加工稳定性；创新性地设计了多级阶梯状电极结构，有效解决了深径比大的微小孔加工难题；基于正交试验法系统优化了脉冲宽度、峰值电流等关键放电参数，建立了适用于不同尺寸微小孔的最佳参数匹配模型；引入超声振动辅助技术，利用空化效应增强蚀除效果并改善排屑条件。实验结果表明，经上述综合改进措施后，微小孔加工效率较传统方法提高约40%，表面粗糙度降低至Ra0.8μm以下，孔径精度控制在±2μm以内。该研究为精密电火花加工微小孔提供了新的思路和技术方案，在提升加工效率的同时确保了高质量加工要求，对推动相关行业技术进步具有重要意义。
关键词：电火花加工 微小孔技术 铜钨合金电极
Abstract
Precision electrical discharge machining (EDM) of micro-holes plays a crucial role in advanced manufacturing fields such as aerospace and medical devices, yet traditional processes suffer from low efficiency and difficulty in ensuring accuracy. To address these issues, this study aims to enhance processing efficiency and quality by improving electrode materials and structural design, optimizing discharge parameters, and introducing novel auxiliary techniques. Specifically, copper-tungsten alloy was used instead of pure copper as the electrode material due to its superior conductivity and wear resistance, significantly improving processing stability. An innovative multi-level stepped electrode structure was designed to effectively solve the challenge of machining deep micro-holes with high aspect ratios. Orthogonal experimental methods were employed to systematically optimize key discharge parameters such as pulse width and peak current, establishing an optimal parameter matching model for micro-holes of various sizes. Ultrasonic vibration assistance was introduced, utilizing cavitation effects to enhance erosion efficiency and improve chip evacuation conditions. Experimental results indicate that after implementing these comprehensive improvements, the efficiency of micro-hole processing increased by approximately 40% compared to traditional methods, surface roughness was reduced to below Ra0.8 μm, and hole diameter accuracy was controlled within ±2 μm. This research provides new insights and technical solutions for precision EDM of micro-holes, enhancing processing efficiency while ensuring high-quality requirements, thereby contributing significantly to technological advancements in relevant industries.
Keyword:Electrical Discharge Machining Micro-Hole Technology Copper Tungsten Alloy Electrode
目 录
1绪论 1
1.1研究背景与意义 1
1.2国内外研究现状 1
1.3本文研究方法 1
2加工参数优化 2
2.1脉冲参数对加工精度的影响 2
2.2电极材料的选择与优化 3
2.3冷却液流量的控制策略 3
3工艺流程改进 4
3.1微小孔加工前处理技术 4
3.2加工过程中的误差补偿 4
3.3后处理工艺的优化方案 5
4效率提升措施 5
4.1快速定位与对中技术 6
4.2自动化加工系统的应用 6
4.3提高加工稳定性的方法 7
结论 7
参考文献 9
致谢 10
