Zhihua Sha

Study on the Gap Flow Simulation in EDM Small Hole Machining with Ti Alloy

In electrical discharge machining (EDM) process, the debris removed from electrode material strongly affects the machining efficiency and accuracy, especially for the deep small hole machining process. In case of Ti alloy, the debris movement and removal process in gap flow between electrodes for small hole EDM process is studied in this paper. Based on the solid-liquid two-phase flow equation, the mathematical model on the gap flow field with flushing and self-adaptive disturbation is developed. In our 3D simulation process, the count of debris increases with number of EDM discharge cycles, and the disturbation generated by the movement of self-adaptive tool in the gap flow is considered. The methods of smoothing and remeshing are also applied in the modeling process to enable a movable tool. Under different depth, flushing velocity, and tool diameter, the distribution of velocity field, pressure field of gap flow, and debris movement are analyzed. The statistical study of debris distribution under different machining conditions is also carried out. Finally, a series of experiments are conducted on a self-made machine to verify the 3D simulation model. The experiment results show the burn mark at hole bottom and the tapered wall, which corresponds well with the simulating conclusion.

A Simulation Study of Debris Removal Process in Ultrasonic Vibration Assisted Electrical Discharge Machining (EDM) of Deep Holes

When machining a small hole with high aspect ratio in EDM, it is hard for the flushing liquid entering the bottom gap and the debris could hardly be removed, which results in the accumulation of debris and affects the machining efficiency and machining accuracy. The assisted ultrasonic vibration can improve the removal of debris in the gap. Based on dynamics simulation software, Fluent, a three-dimensional (3D) model of debris movement in the gap flow field of EDM small hole machining assisted with side flushing and ultrasonic vibration is established in this paper. The laws of different amplitudes and frequencies and different aspect ratios on debris distribution and movement are quantitatively analyzed. The motion height of debris was observed under different conditions. The research results show that periodic ultrasonic vibration can promote the movement of debris, which is beneficial to the removal of debris in the machining gap. When compared to traditional small hole machining in EDM, the debris in the machining gap were greatly reduced, which ensures the stability of the machining process and improves the machining efficiency.

Thermal–structural coupling analysis of brake friction pair based on the displacement gradient circulation method

In view of the braking process for the megawatt wind turbine brakes, considering the geometric and motion characteristics of brake pads and brake discs, a displacement gradient circulation method is put forward in this article, to resolve the deviation of coupling results caused by the difference of friction effect along the radial/circumferential direction of brake disc, and the thermal–structural coupling analysis of friction pair during the braking process is carried out. A three-dimensional model of transient heat transfer for brake friction pair is built based on the Abaqus software. The heat flow density is loaded by the displacement gradient circulation method, which is used to calculate the frictional heat flow during the braking process. The analysis results show that along the circumferential direction of the brake disc the temperature distribution in the friction zone is non-uniform and the temperature starting from the contact position of the brake disc and the brake pad decreases along the counterclockwise direction. The thermal stress caused by the temperature field during the braking process is the main factor causing the brake disc/pad failure. The effectiveness of the method and the model is verified by the designed inertia braking experiments. The analytical method proposed in this article provides a reference for simulating the friction braking process of large-size disc brakes.

Corrigendum to “Study on the Gap Flow Simulation in EDM Small Hole Machining with Ti Alloy”

In electrical discharge machining (EDM) process, the debris removed from electrode material strongly affects the machining efficiency and accuracy, especially for the deep small hole machining process. In case of Ti alloy, the debris movement and removal process in gap flow between electrodes for small hole EDM process is studied in this paper. Based on the solid-liquid two-phase flow equation, the mathematical model on the gap flow field with flushing and self-adaptive disturbation is developed. In our 3D simulation process, the count of debris increases with number of EDM discharge cycles, and the disturbation generated by the movement of self-adaptive tool in the gap flow is considered. The methods of smoothing and remeshing are also applied in the modeling process to enable a movable tool. Under different depth, flushing velocity, and tool diameter, the distribution of velocity field, pressure field of gap flow, and debris movement are analyzed. The statistical study of debris distribution under different machining conditions is also carried out. Finally, a series of experiments are conducted on a self-made machine to verify the 3D simulation model. The experiment results show the burn mark at hole bottom and the tapered wall, which corresponds well with the simulating conclusion.

Multiobjective structure topology optimization of wind turbine brake pads considering thermal-structural coupling and brake vibration

Brake pads of disc brake play an important role in the stable braking process of a large-megawatt wind turbine. There is always vibration, screaming, and severe nonuniform wear under the effect of both retardation pressure and friction. To solve these issues, this article aims to find a new structure of the brake pads to improve brake performance. A multiobjective structure topology optimization method considering thermal-structural coupling and brake vibration is carried out in this article. Based on topology optimization method of Solid Isotropic Microstructures with Penalization (SIMP), the compromise planning theory is applied to meet the stiffness requirement and vibration performance of brake pads. Structure of brake pads is optimized, and both the stiffness and vibration performance of brake pads are also improved. The disadvantages of single-objective optimization are avoided. Thermal-structural coupling analysis is tested with the actual working conditions. The results show that the new structure meets the stiffness requirement and improves the vibration performance well for the large-megawatt wind turbine. The effectiveness of the proposed method has been proved by the whole optimization process.

The effect of high frequency pulse on the discharge probability in micro EDM

High frequency pulse improves the machining efficiency of micro electric discharge machining (micro EDM), while it also brings some changes in micro EDM process. This paper focuses on the influence of skin-effect under the high frequency pulse on energy distribution and transmission in micro EDM, based on which, the rules of discharge probability of electrode end face are also analysed. On the basis of the electrical discharge process under the condition of high frequency pulse in micro EDM, COMSOL Multiphysics software is used to establish energy transmission model in micro electrode. The discharge energy distribution and transmission within tool electrode under different pulse frequencies, electrical currents, and permeability situation are studied in order to get the distribution pattern of current density and electric field intensity in the electrode end face under the influence of electrical parameters change. The electric field intensity distribution is regarded as the influencing parameter of discharge probability on the electrode end. Finally, MATLAB is used to fit the curve and obtain the distribution of discharge probability of electrode end face.

Study on Gap Flow Field Simulation in Small Hole Machining of Ultrasonic Assisted EDM

When machining a small hole with high aspect ratio in EDM, it is hard for the flushing liquid entering the bottom gap and the debris could hardly be removed, which results in the accumulation of debris and affects the machining efficiency and machining accuracy. The assisted ultrasonic vibration can improve the removal of debris in the gap. Based on dynamics simulation software Fluent, a 3D model of debris movement in the gap flow field of EDM small hole machining assisted with side flushing and ultrasonic vibration is established in this paper. When depth to ratio is 3, the laws of different amplitudes and frequencies on debris distribution and removal are quantitatively analysed. The research results show that periodic ultrasonic vibration can promote the movement of debris, which is beneficial to the removal of debris in the machining gap. Compared to traditional small hole machining in EDM, the debris in the machining gap is greatly reduced, which ensures the stability of machining process and improves the machining efficiency.

Study on Abrasive Wear of Brake Pad in the Large-megawatt Wind Turbine Brake Based on Deform Software

For the friction and wear issues of brake pads in the large-megawatt wind turbine brake during braking, this paper established the micro finite element model of abrasive wear by using Deform-2D software. Based on abrasive wear theory and considered the variation of the velocity and load in the micro friction and wear process, the Archard wear calculation model is developed. The influence rules of relative sliding velocity and friction coefficient in the brake pad and disc is analysed. The simulation results showed that as the relative sliding velocity increases, the wear will be more serious, while the larger friction coefficient lowered the contact pressure which released the wear of the brake pad.