空间曲面电火花线切割CAD/CAM系统

为解决高速走丝电火花线切割机床加工空间曲面的难题,实现大锥度空间复杂曲面零件的加工,以空间曲面数学模型和数控模型为基础,开发了一种计算机辅助设计/计算机辅助制造(Computer aided design/computer aided manufacturing,CAD/CAM)系统.其硬件系统以研制的数控转摆摆工作台为核心装置,并与现有高速走丝电火花线切割机床结合,组成空间曲面线切割加工系统.其软件系统可以根据上下导线的参数方程进行分析计算,建立空间曲面的三维模型,自动生成NC加工代码,进行加工仿真和空间曲面零件的加工.利用本系统进行典型空间复杂曲面零件的加工试验,结果表明加工结果与仿真结果基本相似.此外,还分析数控模型以及回摆间隙角对加工误差的影响.这些工作为解决高速走丝电火花线切割加工空间曲面的难题打下基础.     

空间曲面线切割多轴联动加工系统开发及应用

开发了能实现空间曲面零件电火花线切割加工的多轴联动加工系统,分析了系统的组成和运动参数。依据空间解析几何直纹曲面形成原理,建立了五轴联动加工的数学模型体系,获得了五轴联动加工三导线曲面零件的数学模型。研制了多轴联动加工系统的执行机构转摆摆数控工作台及数控系统,加工出理想的实验样件。解决了空间曲面零件的加工难题,拓宽了高速走丝电火花线切割加工的应用范围。该方法在模具制造及空间曲面零件加工中得到广泛应用。     

电火花线切割车削机床的研究及实现

介绍了数控电火花线切割车削机床的机械结构及利用旋转主轴进行的加工.电火花线切割车削机床利用数控线切割机床新增加的旋转轴,不仅可以加工大锥度的圆台,还可以加工形状复杂的空间曲面零件.为解决快走丝电火花线切割加工空间曲面的难题打下基础,具有较高的应用和推广价值.     

线切割五轴联动加工技术开发与仿真

为解决复杂曲面零件的加工难题,开发了以"转、摆、摆数控工作台"为核心的复杂曲面电火花线切割加工系统.分析了复杂曲面线切割加工的运动规律,提出电火花线切割五轴加工计算机仿真技术研究方法.通过运行相应的仿真程序,可以在计算机上直接观察到电火花线切割加工的全部过程,获得了比较理想的仿真结果.开发出一套加工性能稳定的五轴联动电...     

数控电火花线切割加工参数优选的试验研究

针对数控高速走丝电火花线切割加工中的电参数的选取,本文运用二次通用旋转组合设计方法进行了工艺数据试验,提出了针对人工神经网络建模的数据预处理方法,建立了基于BP神经网络的电火花线切割加工参数模型。该模型可有效地反映高速走丝电火花线切割加工的工艺规律,实现在指定加工要求下的加工参数的优化选取。     

探讨高速走丝电火花线切割加工断丝故障分析及预防

高速走丝电火花线切割加工能够满足我国模具制造以及机械加工的需要,但是在高速走丝电火花线切割加工的过程中容易出现断丝的情况,这对于快速的机械加工以及模具制造而言有着非常大的影响。详述高速走丝电火花线切割加工的原理、高速走丝电火花线切割加工断丝的故障原因以及高速走丝电火花切割加工中断丝故障的解决方法及预防。对于高速走丝电火花线切割加工中断丝的情况要进行分析并预防。     

影响高速走丝线切割加工质量的因素分析

综述了高速走丝电火花线切割加工的质量指标，分析了高速走丝电火花线切割加工精度的影响因素，并提出了提高加工精度的相应措施。     

浅谈我国电火花线切割发展方向

谈到电火花线切割加工,国人首先想到的是高速走丝电火花线切割加工。高速走丝电火花线切割机作为我国独创技术的机种,已成为我国数控机床中产量最大、应用最广的机种之一。据估计,目前我国高速走丝电火花线切割机年销售量已达3万台左右,全国有十多万台高速走丝电火花线切割机正在模具制造和零件加工中发挥着重要的作用。     

提高电火花线切割加工精度的几种因素的探讨

通过对数控快走丝电火花线切割加工原理的理解,介绍了影响线切割机床加工精度的几种因素,如:主要工艺指标、放电参数、走丝系统,工作液及其解决方案。     

特种加工机床分会团体标准通过专家审查

由中国机床工具工业协会特种加工机床分会制定的《数控往复走丝电火花线切割机床 性能评价规范》团体标准于2021年4月13日在北京通过专家审查. 数控往复走丝电火花线切割机床是我国独创的电加工机床产品.经过近半个世纪的发展,通过借鉴、创新、提升,数控往复走丝电火花线切割机床的装备技术和工艺水平有了突破,由以往的一次切割加工...     

高低双速走丝电火花线切割工艺试验研究

阐述了高低双速走丝电火花线切割机的设计概念、实现方式和特点。通过一次高速走丝大能量切割、多次单向低速走丝切割并加大电极丝张力等措施,与高速走丝多次切割(中走丝)方式进行了对比试验。结果表明高低双速走丝的切割精度、腰鼓形均比中走丝切割方式有明显改善,而表面粗糙度值则略有提高。     

快走丝电火花线切割加工仿真系统

通过神经网络技术建立了快走丝电火花线切割加工工艺模型 ,利用穷举法建立了具有一定人工智能的工艺参数全局优化系统 ,开发了模具电火花加工过程仿真系统。该系统不仅可以精确预测加工效果 ,而且克服了工艺参数表的局限性 ,弥补了建立在工艺参数表基础上的参数自动选取系统的缺陷 ,实现了工艺参数全局最优化。测试结果及实际使用结果表明本文所建立的仿真系统反映了机床的加工工艺特性 ,预测误差基本控制在 8%内 ,系统的参数优化选取功能使机床的加工性能得以充分发挥。仿真系统具有广泛的通用性 ,可适用于不同类型的线切割加工机床。     

基于TL5040B中走丝线切割机床多次切割工艺参数设置的研究

在国内电加工界对高速电火花线切割机床上的多次切割加工的研究基础上,结合TL5040B中走丝线切割机床的应用,阐述高速走丝多次切割的基本条件,以及多次切割过程中各种工艺参数的确定。在中走丝线切割数控机床TL5040B进行了工件多次切割工艺的试验研究,取得了预期效果,这对于企业在现有的条件下提高加工水平具有一定的指导意义。     

电火花线切割技术的研究现状及发展趋势

对电火花线切割加工技术的现状进行了分析。并对新型走丝系统、高度自动化及人工智能技术、高速走丝的多次切割技术、微细电火花线切割加工技术等方面的最新进展进行了概述。     

The effect of the cutting parameters on performance of WEDM

In this study, variations of cutting performance with pulse time, open circuit voltage, wire speed and dielectric fluid pressure were experimentally investigated in Wire Electrical Discharge Machining (WEDM) process. Brass wire with 0.25 mm diameter and AISI 4140 steel with 10 mm thickness were used as tool and work materials in the experiments. The cutting performance outputs considered in this study were surface roughness and cutting speed. It is found experimentally that increasing pulse time, open circuit voltage, wire speed and dielectric fluid pressure increase the surface roughness and cutting speed. The variation of cutting speed and surface roughness with cutting parameters is modeled by using a regression analysis method. Then, for WEDM with multi-cutting performance outputs, an optimization work is performed using this mathematical models. In addition, the importance of the cutting parameters on the cutting performance outputs is determined by using the variance analysis (ANOVA).     

Modeling and multiresponse optimization on WEDM for HSLA by RSM

Wire electric discharge machining (WEDM) is a nonconventional machining method to cut hard and conductive material with the help of a moving electrode. High-strength low-alloy steel (HSLA) is a hard alloy with high hardness and wear-resisting property. The purpose of this study is to investigate the effect of parameters on cutting speed and dimensional deviation for WEDM using HSLA as workpiece. It is seen that the most prominent factor for cutting speed and dimensional deviation is pulse-on time, while two-factor interactions play an important role in this analysis. Response surface methodology was used to optimize the process parameter for cutting speed and dimensional deviation. The central composite rotatable design was used to conduct the experiments. The analysis of variance was used for the investigation of significant factors.     

Fabricating micromilling tool using wire electrodischarge grinding and focused ion beam sputtering

In the present research, wire electrical discharge machining (WEDM) of γ titanium aluminide is studied. Selection of optimum machining parameter combinations for obtaining higher cutting efficiency and accuracy is a challenging task in WEDM due to the presence of a large number of process variables and complicated stochastic process mechanisms. In general, no perfect combination exists that can simultaneously result in both the best cutting speed and the best surface finish quality. This paper presents an attempt to develop an appropriate machining strategy for a maximum process criteria yield. A feed-forward back-propagation neural network is developed to model the machining process. The three most important parameters – cutting speed, surface roughness and wire offset – have been considered as measures of the process performance. The model is capable of predicting the response parameters as a function of six different control parameters, i.e. pulse on time, pulse off time, peak current, wire tension, dielectric flow rate and servo reference voltage. Experimental results demonstrate that the machining model is suitable and the optimisation strategy satisfies practical requirements.     

Determining cutting parameters in wire EDM based on workpiece surface temperature distribution

The material removal process in wire electrical discharge machining (WEDM) may result in work-piece surface damage due to the material thermal properties and the cutting parameters such as varying on-time pulses, open circuit voltage, machine cutting speed, and dielectric fluid pressure. A finite element method (FEM) program was developed to model temperature distribution in the workpiece under the conditions of different cutting parameters. The thermal parameters of low carbon steel (AISI4340) were selected to conduct this simulation. The thickness of the temperature affected layers for different cutting parameters was computed based on a critical temperature value. Through minimizing the thickness of the temperature affected layers and satisfying a certain cutting speed, a set of the cutting process parameters were determined for workpiece manufacture. On the other hand, the experimental investigation of the effects of cutting parameters on the thickness of the AISI4340 workpiece surface layers in WEDM was used to validate the simulation results. This study is helpful for developing advanced control strategies to enhance the complex contouring capabilities and machining rate while avoiding harmful surface damage.