电火花成型辅助设计与加工仿真系统的开发

研究了电火花成型（EDM）中因电极平动所造成的加工误差，提出了其于二维及三维的电极平动补偿方法，开发了以UG系统为平台的电极平动补偿及加工仿真系统，并进行了仿真对比实验。实验表明，该系统可以有效提高EDM电极设计的效率。     

精密模具EDM专用补偿软件系统的开发

针对电火花成形加工(SEDM)电极平动的不同类型,提出了电极补偿修正原理,开发了SEDM专用补偿软件系统,并进行了实验验证.实验表明,该系统能有效降低因电极平动所产生的误差,明显提高SEDM加工精度.     

平动电极的球刀加工分析

分析了平动电极与普通放电加工中电极的工作原理,得出电极的运动轨迹不同,导致电极相对工件的尺寸、形状不同,如果直接用球刀加工平动电极,会导致电极的形状不能满足平动加工的要求。针对这一问题,根据不同的电极形状分别采用了分割、改变圆角或斜角尺寸、平移等方法,用球刀加工出了合格的平动电极。为采用球刀加工平动电极提供了一条思路。     

电极加工自动编程系统的研究与开发

提出了一种以表面为线索对电极进行加工特征分析,电极加工工艺方案和刀路自动生成的编程方案;完成电极加工后,自动提取电极的实际测量尺寸,分析加工误差并进行补偿,自动生成放电代码;最后自动生成程序清单和EDM放电加工图。系统基于NX和VS平台开发,并通过大量实例验证,能显著提高生产效率,获得生产实际应用。     

一种微细EDM电极的制造方法

针对微细EDM异形电极的加工难题，提出了利用同步辐射深度光刻和电铸技术相结合制造EDM电极的方法，可望较好地解决异形电极的制造问题。     

电极设计问题探讨

电火花加工(EDM)是模具制造的重要方法,电极设计对EDM加工至关重要。本文通过实例深入浅出的探讨了电极设计过程中主要问题,对实际生产有一定的指导意义。     

碳化硅反射镜安装面电火花平动加工工艺研究

针对大型Si C反射镜的加工需求,提出了一种电火花平动加工工艺。通过改造电火花线切割机床,搭建了加工实验平台,设计了采用内部高速高压冲液方式的电火花平动加工电极。在此基础上,以大型Si C反射镜为加工对象进行实验,验证了该工艺方法的可行性。     

基于UG的手机外壳型芯的电极设计与加工

以手机外壳型芯为例,基于UG软件用电极设计模块与建模模块相结合的方法进行了主要电极的设计,并完成主体电极的EDM工程图,采用优化的数控加工工艺对模具零件进行数控编程加工。实验结果表明该零件的加工质量达到了预期的要求,为模具型芯的电极设计和加工提供了设计思路和方法。     

基于圆锥形端面电极的电火花铣削加工定长补偿方法研究

电极损耗对工件质量的影响显著,为保证电火花铣削加工精度,需要对工具电极损耗给予补偿。定长补偿下配合旋转电极,得到圆锥形电极端面,随后根据定长补偿方法给出了补偿长度的计算公式。实验发现,补偿精度值对工件加工精度有较大影响,随着补偿精度值的增大,加工精度逐渐降低,适当选择较小的补偿精度值,能获得良好的加工效果。     

EDM石墨电极材料及选择方法

叙述了电极材料的种类，重点介绍了石墨电极性能特点与分类，并介绍了EDM加工中，电极材料的选用方法及应用实例。     

Real-time Tool Wear Compensation in Milling EDM

Accurate machining by milling EDM (i.e. CNC contouring EDM with a rotating cylindrical or tubular electrode) necessitates compensation of the tool electrode wear. Existing anticipated wear compensation is based on off-line tool wear simulation prior to machining. This can be combined with corrections based on periodical measurements of tool length during machining. Anticipated wear compensation involves an important restriction: an exact model of the blank geometry must be available in order to perform the tool wear simulation. This paper presents a new method of wear compensation. On-line estimation of tool wear is used for combining anticipated compensation with real-time compensation. This extends the scope of milling EDM to the machining of blanks of which the exact shape is not known in advance.     

微细电火花铣削工件侧面轮廓加工研究

开展了不同分层厚度电火花铣削侧面轮廓加工研究,通过改变线性补偿值,研究不同补偿率下的电极形状与稳定铣削深度,获得了较大分层厚度下的恒定深度铣削槽;分析总结了锥形电极的形成与稳定原因和不同补偿量对电火花铣槽影响的相关规律;通过线性补偿法对圆弧形片状工件和具有一定倾角工件的侧面加工铣削,验证了实验规律。     

油泵油嘴复杂微结构微细电火花铣削加工试验

为解决油泵油嘴复杂微结构加工难题,开展了微细电火花铣削加工试验研究。在改进微细电火花加工机床系统的基础上,介绍了微细电火花铣削加工试验过程,并着重分析电极损耗补偿问题、加工效率问题的解决方法,进而完成油泵油嘴复杂微结构的精密微细电火花加工,总结出保证微细电火花铣削加工质量和加工效率的工艺规律。     

Tool path generation for 4-axis contour EDM rough machining

Contour or CNC EDM machining of free-form surfaces requires tool paths that are different from those used in mechanical milling although in geometry both processes are described by the similar model of intersection between the rotating tool and the workpiece. In this paper, special requirements on tool paths demanded by contour EDM machining are studied and a two-phase tool path generation method for 4-axis contour EDM rough milling with a cylindrical electrode is developed. In the first phase of the method, initial tool paths for virtual 3-axis milling are generated in a commercial CAD/CAM system—Unigraphics, which provides users with plenty of options in choosing suitable tool path patterns. From these tool paths, cutter contact (CC) points between electrode and workpiece are reversely calculated. In the second phase, considering the special requirements of EDM machining, which include discharging gap compensation, electrode wear compensation, DC arcing prevention, etc., the electrode is adjusted to an optimized interference-free orientation by rotating it around the CC points obtained in the previous phase. This new orientation together with the reference point of electrode is output as new tool path. The whole algorithm has been integrated into Unigraphics, machining simulations and tests have been conducted for 4-axis contour EDM rough machining.     

复杂型面多轴电火花加工的电极损耗补偿

在复杂型面的多轴电火花加工中,电极损耗对加工精度具有影响显著,因此,对电极损耗进行准确补偿非常重要。通过研究得出电极表面损耗与电场强度有关,并建立了电极损耗系数与电场强度之间的关系。在此基础上,提出了考虑电极运动路径的电极损耗补偿方法,并通过加工实验证明了该方法的准确性与有效性。     

模具电火花电极的智能化设计

随着塑料制品日趋精密化和复杂化,模具需要电火花加工的部分越来越多,电极设计的工作量很大。因此有必要进行电极设计的自动化和智能化技术的研究。介绍了电极自动设计中需电火花加工区域的自动识别和复杂形状电极的拆解等关键算法。并给出了电火花电极智能设计系统的框架。该系统的运行表明,一个智能化的电极设计系统可以有效地提高电极设计效率。     

工作液超声振动辅助电火花小孔加工装置设计与试验

电火花加工小孔存在电蚀产物排出效率低导致加工效率低、电蚀产物排除导致二次放电现象影响加工精度等问题,而超声振动在工作液中产生空化效应和泵吸作用,能大幅提高电火花的排屑和消电离能力,进而在很大程度上减少上述问题的发生。设计一套工作液超声振动辅助电火花小孔加工装置,主要包括主轴系统、微三维运动平台、超声振动工作液槽和数据采集系统,其中主轴系统包括NSK电主轴、引电结构、工具电极装夹结构,可以实现工具电极的高速旋转;基于LabVIEW开发了电火花小孔加工控制系统,主要包括初始化模块、粗定位模块、恒电压对刀模块、实时电压分段控制加工模块和实时显示模块。开展了工作液超声振动辅助电火花小孔加工试验研究,试验结果表明：随电火花加工电压的增加,工件材料去除率和电极损耗率都趋于增大。     

Compensation of electrode orbiting in electrical discharge machining based on non-uniform offsetting

In orbiting EDM, the orbital motion of electrode makes the cavity dimension in the workpiece deviate from the design objective. This paper presents a compensation method for electrode orbiting. The presented techniques are used to modify the geometric shape of free-form electrode, so as to eliminate the effects to the cavity dimension that arise from the electrode orbiting. The basic approach consists of three steps: (1) NURBS parameters extraction of electrode surfaces and surface adaptive sampling; (2) non-uniform offsetting of the sampled points according to the orbiting patterns; (3) approximation of non-uniform offset surface under error control. And the method to handle trimmed surface in compensation is also discussed. Quite a few implemented examples and machining results show that the developed techniques can compensate the orbital motion and improve the machining precision effectively.     

模具型腔电极的设计及其应用

以孔形型腔和手机模具型腔为例,探讨两种情形下电极的设计以及根据电极的实际加工尺寸和机床的加工参数表选择电火花加工参数的过程,以便在实践中更好地掌握电火花加工技术。