Simulation Of Temperature Field And Erosion Amount Of WEDM In Gas Based On ANSYS

With the rapid development of science and technology,people's requirements on the precision of some parts of industrial products have become higher and higher.WEDM in gas has small processing surface roughness,narrow discharge gap,no electrolytic corrosion machining surface,good straightness and so on.It is suitable for finishing.People found that the WEDM process is a very complex electrical and physical process.At present,for the study of the WEDM in gas processing mechanism is only a few,the lack of accurate prediction of the machining process,so that the analysis of WEDM in gas test phenomenon lacks in-depth theoretical basis.It is necessary to study further on the discharge mechanism of WEDM in gas.Transient temperature field of WEDM in gas single pulse discharge is analyzed by using finite element analysis software ANSYS,the workpiece material is Cr12 Mo V;and on the basis of the temperature field,assuming that the molten part was incompressible viscous flow,the fluid field was analyzed,simulate the discharge erosion pit surface topography with a raised edge under three typical processing conditions.To simplify the calculation of the erosion amount of WEDM,simplified the erosion pits model from the finite element simulation to a spherical cap,and confirmed its legitimacy.Analysis the main distribution of the discharge erosion pits of different intensity.Use 3d software shows the workpiece surface morphology after removed by different intensity of discharge corrosion pit,introduces the calculation method of the volume removed by a large number of discharge corrosion pit on the workpiece surface.The paper established the model of erosion amount of uniformly distributed discharge erosion pits under the continuous discharge condition.Take discharge corrosion pit exist only between corrosion pit level 1,secondary overlap state after processing a period of time for example,deduce the calculation formula of level 1 and secondary overlap part removed volume,and summarizing the calculation formula of the overlapping volumewhen two overlapping of arbitrary size same spherical cap under the condition of its distance from each other was known;deduced removal volume formula of single discharge erosion pit.Process the workpiece by rough machining and finishing in gas with different electrical parameters.Processing while using WEDM discharge status detection system for detecting discharge status,and at the same time WEDM discharge point position was detected,get the position distribution of the discharge point and the percentage of effective spark of Cr12 Mo V under the condition of different finishing parameters in gas.Detect the processing results;obtain the erosion amount of the actual processing.Take a spherical cap as a single discharge erosion pit model;calculate the erosion amount of continuous pulse discharge.Calculated parts of the theoretical erosion amount and its correction value of white layer,then obtain the error rate between the correction value and the actual erosion amount.Comparing the theoretical erosion amount with the actual erosion amount,obtain the volume of the anti-stick part;calculate the thickness of the anti-stick layer.Lay the foundation for the research of the distribution of the discharge erosion pits and the microscopic removal volume on WEDM.