用正交试验分析中电参数对圆柱度影响

电火花加工脉冲放电的统计学研究表明电参数与加工质量间存在一定的规律性。为实现电火花加工小孔圆柱度误差的合理控制,通过大量的工艺试验研究放电参数与小孔圆柱度间的规律是十分必要的。提出了多截面直角坐标测量方法,实现了小孔圆柱度的定量评定。在此基础上,采用正交试验研究了放电参数（开路电压、电流,脉宽,脉间,抬刀周期）对小孔圆柱度的影响。结果表明：脉宽对圆柱度的影响最为显著,开路电压次之,其余三个参数的影响较弱;同时也得到了以圆柱度误差最小为评价目标的一组放电参数。     

一种电火花加工单脉冲电源的研制

电火花加工过程可以认为是由连续的单个脉冲放电累加形成的结果。在电火花加工过程中,单个脉冲放电可以体现等离子体的精确性,通过研究单个脉冲的放电特点能方便分析放电蚀坑的特性,从而有利于利用单脉冲放电特点了解电火花加工过程,因此,研究单脉冲电源具有重要的作用。以AT90S8535单片机为核心芯片,完成用于电火花基础研究的独立式单脉冲电源的设计,主要介绍电源的主振控制电路、功率开关驱动电路以及检测电路的设计。在空气介质中进行单脉冲放电试验,获得了脉宽为5、50、180、400和800μs的放电电压波形,验证了脉冲电源设计的合理性。该脉冲电源可用于电火花单脉冲加工基础研究。     

用正交试验分析电参数对小孔圆柱度的影响

为实现电火花加工小孔圆柱度误差的合理控制,通过工艺试验研究了放电参数与小孔圆柱度间的规律。提出了多截面直角坐标测量方法,用线切割对已加工小孔的工件进行轴向和径向切割,以产生反映小孔特征的母线基准和圆基准;然后,用万能工具显微镜对这两个基准上的特征点进行测量,最终实现小孔圆柱度的定量评定。在此基础上,采用正交试验研究了放电参数(开路电压、电流,脉宽,脉间,抬刀周期)对小孔圆柱度的影响。结果表明,脉宽对圆柱度的影响最为显著,开路电压次之,其余3个参数的影响较弱;实验获得了以圆柱度误差最小为评价目标的一组放电参数:开路电压110V,电流0.6A,脉宽150μs,脉间120μs,抬刀周期1+2s。验证实验得到了平均半径为0.30184mm的小孔,其圆柱度误差为0.021mm,说明用该方法控制电火花加工小孔的圆柱度是有效的。     

基于单片机的脉宽可调低频高压脉冲电源

本文介绍了一种基于单片机的脉宽可调低频高压脉冲电源的设计.该电源输出电压的频率和脉宽可由用户自行设定,同时引入单相交流调压模块实现稳压输出,并使其输出电压在10KV～50KV范围内连续可调,利用单片机控制SG3525工作时间形成高压脉冲,并通过单片机的处理实时地将电源输出电压幅值、频率和脉宽显示在液晶屏幕上.     

连杆尖锐裂解槽的脉冲YAG激光切割

对激光加工连杆裂解槽工艺进行了研究,根据材料状态、能量平衡和孔形变化,将脉冲激光加工裂解槽孔过程分为起始、准稳定破坏及收尾3个阶段;对脉宽、波形、脉冲频率、切割速度等影响裂解槽槽根半径的因素进行了分析;设计了一种新的激光脉冲波形,以满足槽根尖锐度的要求。分析及实验结果表明:长脉冲宽度与切割速度的合理匹配是获得尖锐裂解槽的关键,当脉宽取1ms,切割速度为10mm/s时,获得了根部尖锐的裂解槽。对于要求深且尖锐的裂解槽,可增加频率转化为多个长脉冲加工;当频率增加到40Hz,脉宽取0.5ms,得到的裂解槽纵横比大且根部尖锐。裂解槽形貌对比表明,对于脉宽和频率进行优化,可在加工裂解槽孔的各个阶段合理地注入能量,获得高质量的裂解槽。     

斜率与变统计周期微细电火花脉冲识别系统

针对电压阈值法不能很好统计开路时长和改变放电电压时需要调节电压阈值等问题。提出一种基于斜率比值和变统计周期的脉冲识别方法,该方法使检测装置直接用于微细电火花粗磨、精磨两种不同开路电压的加工情形中,不需要调节电压阈值且能有效的统计开路时长,从而提高检测效率和精度。首先使用NI采集卡和LabVIEW软件开发脉冲识别系统,该系统可对间隙电压进行显示、连续存储以及对文件进行拆分,接着对斜率比值法和变统计周期法进行理论分析并编写脉冲识别与统计程序,最后进行放电状态检测的实验验证。结果表明：该方法能够识别不同脉冲且适用于不同放电电压情形,程序结果与实际结果较吻合,证明了该方法的有效性和实用性。     

高重频短脉冲输出的增益开关型Nd~(3+)∶YVO_4微片激光器

以直流偏置叠加脉冲电流驱动的半导体激光器(LD)作为抽运源,端面抽运Nd3+∶YVO4平-平腔微片激光器。利用增益开关技术,调节LD驱动电流的幅值、脉宽可改变输出激光的脉宽,改变LD驱动电流的重复频率可改变输出激光的重复频率,实现了单模稳定、可控高重复频率的小型、全固化短脉冲激光器,可作为理想的脉冲激光种子光源,应用于激光测距、激光雷达等领域。     

空气中高压脉冲电晕放电N2的光谱实验研究

利用发射光谱法 ,在常温常压下对空气中高压脉冲电晕放电 N2 发射光谱相对强度进行了测量。实验结果表明 :无论正脉冲电晕放电还是双极性脉冲电晕放电 ,N2 的辐射光强都随脉冲电压峰值、放电重复频率的升高而增大。     

高重频短脉冲输出的增益开关型Nd^3＋：YVO4微片激光器

以直流偏置叠加脉冲电流驱动的半导体激光器(LD)作为抽运源,端面抽运Nd3+∶YVO4平-平腔微片激光器.利用增益开关技术,调节LD驱动电流的幅值、脉宽可改变输出激光的脉宽,改变LD驱动电流的重复频率可改变输出激光的重复频率,实现了单模稳定、可控高重复频率的小型、全固化短脉冲激光器,可作为理想的脉冲激光种子光源,应用于激光测距、激光雷达等领域.     

光泵浦源重频运行稳定性

为了研究表面放电光泵浦源的重频运行稳定性,以高纯度AlO3陶瓷作为放电基底,研制了重频分段线性表面放电光泵浦源模块,研究了不同条件下泵浦源模块的放电抖动和辐射强度波动.研究发现,当重复频率在1～10 Hz时,泵浦源的放电抖动主要受充电电压、触发脉冲电压和放电间隙长度的影响,随运行频率的变化较小;辐射强度波动主要与充电电...     

Increasing discharge energy of micro-EDM with electrostatic induction feeding method through resonance in circuit

This paper describes the method to increase discharge energy in micro-EDM using electrostatic induction feeding as the pulse generator. In a previous study, controlled pulse train method was introduced to increase discharge energy and enlarge unit removal per discharge by allowing multiple discharges to occur at the same spot. During observation, it was found that the oscillation of discharge current is excited at higher amplitude even if the same capacitance is used. In this paper, the influence of frequency on discharge energy was investigated. It was found that higher discharge energy can be obtained when machining was done at the resonant frequency of the circuit. Influence of capacitance and inductance on resonant frequency was studied. Probability of discharge continuity at different frequencies was examined. The results confirmed that higher discharge continuity within the pre-determined pulse train duration can be achieved when machining is conducted at resonant frequency, leading to higher material removal rate (MRR).     

An experimental study on micro wire-EDM of polycrystalline diamond using a novel pulse generator

This paper presents a new pulse generator for cutting of polycrystalline diamond (PCD) by micro wire electrical discharge machining (micro wire-EDM). The pulse generator using anti-electrolysis circuitry and digital signal processor-based pulse control circuit was developed to suppress damages on the machined surface of PCD while achieving stable machining. A novel pulse control method was proposed to provide high-frequency pulse control signals with a period of off duty cycle for reionization of the dielectric in the spark gap so as to reduce the consecutive occurrence of short circuits. A series of experiments were carried out to investigate the effect of open voltage on machining performance in terms of material removal rate, slit width, thickness of the damaged layer on machined surface, and surface finish. An increase of open voltage increases peak current, thus producing greater discharge energy and, thereby, contributing to improvements in material removal rate, but leading to larger slit width and thickness of the damaged layer and worse surface finish. Experimental results not only demonstrate that the developed pulse generator could achieve satisfactory machining results but also have verified the applicability of this new technique in micro wire-EDM.     

Design and experimental study of a power supply for micro-wire EDM

This paper presents the development and application of a new power supply in micro-wire EDM. A transistor-controlled power supply composed of a low-energy discharge circuit and an iso-frequency pulse control circuit was designed to provide the functions of high frequency and lower energy pulse control. Pulse states are classified as open circuit, normal spark, arc discharge and short circuit by means of the level of gap voltage and associated discharge current. A power supply test revealed that a high current-limiting resistance results in a decrease of discharge current. Peak current decreases with an increase of pulse-control frequency. Experimental results not only demonstrate that the iso-frequency pulse generator can provide low-energy pulses with a frequency of 185 kHz and a discharge current of 0.7 A, they also verify the applicability of the developed power supply in micro-wire EDM.     

小孔加工电火花脉冲电源实验研究

针对传统脉冲电源普遍存在的电能利用率低、电阻发热严重、散热设备庞大等问题,提出了一种取消限流电阻的电火花脉冲电源结构。电源由PWM控制器、DC/DC变换器、加工脉冲时序发生器等组成。电源本身具有自动调节输出电压的功能,可实现空载击穿电压、脉冲宽度、脉冲间隔独立可调,取消了体积庞大的工频变压器。通过多次小孔加工实验获得了脉冲电源加工过程中电极损耗率、小孔椭圆度以及单边放电间隙等和电源稳定性相关参数的数据曲线,所得数据表明电源具有较好的加工稳定性和可靠性。     

基于 CPLD的双通道高压脉冲信号源

针对声波测井压电陶瓷换能器容性大的负载特性,采用单片机和CPLD相结合的方式设计了一种输出幅度高、驱动电流大、脉冲宽度可调的双通道高压脉冲信号源。系统利用C8051F350单片机及PWM控制芯片MM33060A,并结合自耦变压器反激式升压电路将12 V直流供电电压抬升至300 V。采用CPLD产生精确的频率可控的300 V脉冲电压,利用脉冲变压器进一步提升电压,得到了上千伏的高压激励脉冲。实验结果标明,设计的信号源在激励压电陶瓷换能器时,负载上得到了比较理想的波形,波形上升沿陡峭,无拖尾及振荡现象,满足实际应用需求。     

Design and performance of a pulse transformer based on Fe-based nanocrystalline core

A dry-type pulse transformer based on Fe-based nanocrystalline core with a load of 0.88 nF, output voltage of more than 65 kV, and winding ratio of 46 is designed and constructed. The dynamic characteristics of Fe-based nanocrystalline core under the impulse with the pulse width of several microseconds were studied. The pulse width and incremental flux density have an important effect on the pulse permeability, so the pulse permeability is measured under a certain pulse width and incremental flux density. The minimal volume of the toroidal pulse transformer core is determined by the coupling coefficient, the capacitors of the resonant charging circuit, incremental flux density, and pulse permeability. The factors of the charging time, ratio, and energy transmission efficiency in the resonant charging circuit based on magnetic core-type pulse transformer are analyzed. Experimental results of the pulse transformer are in good agreement with the theoretical calculation. When the primary capacitor is 3.17 μF and charge voltage is 1.8 kV, a voltage across the secondary capacitor of 0.88 nF with peak value of 68.5 kV, rise time (10%-90%) of 1.80 μs is obtained.     

A compact high-voltage pulse generator with opening insulated-gate bipolar transistor switch and a high pulse repetition rate

A small-size high-voltage (～20 kV) microsecond pulse generator, which is based on a pulse transformer and loaded into a reactor with a pulse corona discharge, is described. Insulated-gate bipolar transistors (IGBTs) that form the switch are used in the low-voltage circuit of the generator. When the switch is open, voltage pulses with an amplitude of up to 1000 V are created across it and, hence, across the primary winding of the transformer. The pulse repetition rate of the generator is ～20000 pulses/s.     

A compact repetitive high-voltage nanosecond pulse generator for the application of gas discharge

Uniform and stable discharge plasma requires very short duration pulses with fast rise times. A repetitive high-voltage nanosecond pulse generator for the application of gas discharge is presented in this paper. It is constructed with all solid-state components. Two-stage magnetic compression is used to generate a short duration pulse. Unlike in some reported studies, common commercial fast recovery diodes instead of a semiconductor opening switch (SOS) are used in our experiment that plays the role of SOS. The SOS-like effects of four different kinds of diodes are studied experimentally to optimize the output performance. It is found that the output pulse voltage is higher with a shorter reverse recovery time, and the rise time of pulse becomes faster when the falling time of reverse recovery current is shorter. The SOS-like effect of the diodes can be adjusted by changing the external circuit parameters. Through optimization the pulse generator can provide a pulsed voltage of 40 kV with a 40 ns duration, 10 ns rise time, and pulse repetition frequency of up to 5 kHz. Diffuse plasma can be formed in air at standard atmospheric pressure using the developed pulse generator. With a light weight and small packaging the pulse generator is suitable for gas discharge application.     

PULSE DISCRIMINATION FOR ELECTRICAL DISCHARGE MACHINING WITH ROTATING ELECTRODE

This article presents a new method for discrimination of various types of pulses generated during an electrical discharge machining process in presence of a rotating electrode. Existing pulse discrimination methods do not perform efficiently in an electrical discharge machine with rotating electrode, as arcs rarely occur during the machining process. Our method involves simultaneous comparison of the gap voltage and current signals with various thresholds. The main advantage of our proposed method is its efficient computation and significantly better accuracy in discriminating between various pulse classes for electrical discharge machining devices with rotating electrode. Experimental studies demonstrate a superior performance of our method in distinguishing normal pulses from harmful arcs, open circuit and short circuit pulses, compared with the state-of-art methods.     

An Analysis of Excitation Pulse Adjustable Signal of Ultrasonic Flaw Detection

This research focuses on the influence of the ultrasonic flaw detection circuit on the ultrasonic emission. A software simulation and the super-exploration test are adopted. The characteristics of the transmitting circuit, the spike wave pulse generator and the square wave pulse generator are analyzed by simulating the pulse amplitude, the square wave pulse width and the transmitting pulse damping of the pulse generator. On the basis of simulations and experiments the fact that the best pulse effect relies on a reasonable coordination of pulse width and damping resistance is further verified. By using double-high-speed output power switch, appropriate adjustments on square wave pulse generator help to excite twice the charge voltage than the spike pulse generator can stimulate.