节能型电火花加工脉冲电源的研究

设计了一种采用LCL-T主电路结构的新型节能型脉冲电源系统,给出了系统硬件电路和软件设计思路,分析了脉冲电源主要能耗部分的电能损耗,并且利用设计的脉冲电源样机进行了工艺试验,检验了节能型电火花加工脉冲电源的加工工艺性能,考察了系统方案的可行性,试验证明所设计的节能型脉冲电源具有良好的加工功效。     

WDH—Ⅱ型脉冲电源的设计和使用效果

在电火花线切割加工机床中,脉冲电源性能的优劣,直接影响电火花线切割加工工件表面粗糙度和线切割加工速度。因此,电火花线切割脉冲电源的设计历来为人瞩目。WDH-Ⅱ型脉冲电源的设计,实质上是用TMOS(MOSFE7)场效应管控制输出的分     

新型微能可控的MWEDM脉冲电源

分析了以往的微细电火花线切割加工(MWEDM)脉冲电源的不足。在现代电力电子技术基础上，开发出新型微能可控的微细电火花线切割加工脉冲电源。试验表明，这种高质量的脉冲电源为改善微细电火花线切割加工整体性能、拓展加工领域提供了技术保证。     

节能型电火花加工脉冲电源研究现状及发展趋势

分析了研制节能型电火花加工脉冲电源的实际意义．介绍了几种典型节能电火花加工脉冲电源的工作原理和提高际冲电源电能利用率的不同方法以及各自的特点．提出了节能型电火花加工脉冲电源未来的发展趋势。     

第十二届中国国际机床展览会特种加工机床评述（下）

二、电火花线切割机床（WIRE-CUT）1.国外单向走丝电火花线切割机床国外单向走丝电火花线切割机床的技术发展水平,着重针对电火花线切割加工特点及应用情况,在脉冲电源、自动控制及主机结构等影响线切割加工三大指标的几个关键功能部件上有所创新,并且在实用性、稳定性、可靠性,以及各功能模块的自适应控制性能等方面有所提升（1）脉冲电源技术高效电火花脉冲电源是单向走丝线切割机床的核心单元,高频脉冲电源的自适应控制策略的优劣,对单向走丝线切割的加工效率、加工精度,     

电火花线切割机床高频电源的使用

在火花放电过程中,脉冲电压是产生电火花放电的必要条件,而高频电源就是产生脉冲电压的一个大功率高频脉冲信号源,又称脉冲电源（以下通称为高频电源）,它是数控线切割机床中的一个重要组成部件。在一定条件下,线切割机床的加工效率往往取决于高频电源的性能,因此,在使用过程中高频电源显得尤为重要。下面根据笔者的经验谈谈对高频电源的一些认识。     

能量控制型高效线切割脉冲电源的设计

介绍了能量控制型线切割脉冲电源的基本工作原理，较详细地论述了电源的组成结构及关键模块的设计，该电源可使每个放电脉冲的能量保持一致，从而可以显著提高线切割加工的效率等工艺指标。     

复杂微小零件的微细电火花线切割加工技术研究

在分析微细电火花线切割加工特点的基础上,对获得高精度、高表面质量加工指标的关键技术进行了研究.重点对微能脉冲电源、智能工艺规划系统和加工工作液间隙特性等关键技术进行了研究,解决了微能脉冲电源能量精确可控以及微小复杂零件加工工艺规准的智能决策问题,满足了微细电火花线切割加工的需要.     

基于触摸屏控制具有快速过流保护的WEDM电源研制

设计了各项参数符合某专用电火花线切割机床要求的脉冲电源。该电火花线切割脉冲电源,以PIC18F458单片机内部集成的PWM功能模块产生脉冲信号,频率和占空比调节方便,性能稳定。采用霍尔传感器作为检测过电流的器件,实现快速过流保护的功能,避免过电流对加工的影响。同时设计了基于触摸屏控制的人机交互系统,界面友好,操作方便灵活。经试验表明,整个电源系统性能稳定,减少了过电流产生的不利影响,提高了加工质量。     

高效、大功率高频脉冲电源

一、前言 近年来,线切割加工向着低粗糙度、高效率(高速)、切割厚度大、丝耗小的方向发展。模具加工遂渐向大件和超厚方向发展。从线切割机床的组成来看,达到上述指标是一个综合的结果,但这其中,机床的高频脉冲电源起着至关重要的作用。近二年来,我们对高频脉冲电源做了深入研究,并研制出“YCQ2861全数字集成电路V—MOS高频脉冲电源”产品正式投放市场,在用户中反映较好。     

Experimental study on energy consumption of energy-saving pulse power for WEDM

Wire electrical discharge machining (WEDM) is widely used in aerospace, mold manufacturing, automotive, and other fields. But now, traditional WEDM pulse power contains current-limiting resistor, and its energy utilization rate is low. Meanwhile, discharge energy of WEDM pulse power cannot be accurately controlled, and there is no unified understanding of distribution about discharge energy. In this paper, the pulse power improves energy utilization rate by removing current-limiting resistor and adopting single-arm pulse width modulation control method which controls peak current and modulates long short-circuit pulse width. Experiments proved that the energy-saving pulse power improves energy utilization rate by, approximately, 67.6 % than traditional pulse power. The paper analyzed a single-pulse energy waveform of the energy-saving pulse power and calculated each spark pulse energy and total energy provided by pulse power. It found that gap spark discharge energy only accounted for about 51 % of the energy provided by the pulse power, and other energy was mainly consumed in switching loss of power switch and parasitic resistance of pulse power.     

复合结构电流型WEDM无阻脉冲电源的研究

介绍了一种复合结构电流型电火花线切割无阻脉冲电源,在分析其电路工作原理和电路框图的基础上,重点讨论了双管正激交错并联DC/DC变换器、控制与保护电路的设计,并制作了原理样机.     

基于ISA总线的电火花线切割脉冲电源研究

为了提高电火花加工自动化和智能化程度,更方便地实现电火花加工脉冲电源的实时控制,在现有的脉冲电源基础上开发了一种基于ISA总线的电火花脉冲电源。在系统软件中,编制了电火花加工的电参数数据库,用户能根据数据库中提供的电参数或根据用户的需求方便地设置加工电参数。在硬件系统中采用了AT89C51单片机与8253作为核心产生脉冲信号,结构简单,脉冲周期范围大。     

Influence of machining parameters on surface roughness in finish cut of WEDM

Surface roughness is significant to the finish cut of wire electrical discharge machining (WEDM). This paper describes the influence of the machining parameters (including pulse duration, discharge current, sustained pulse time, pulse interval time, polarity effect, material and dielectric) on surface roughness in the finish cut of WEDM. Experiments proved that the surface roughness can be improved by decreasing both pulse duration and discharge current. When the pulse energy per discharge is constant, short pulses and long pulses will result in the same surface roughness but dissimilar surface morphology and different material removal rates. The removal rate when a short pulse duration is used is much higher than when the pulse duration is long. Moreover, from the single discharge experiments, we found that a long pulse duration combined with a low peak value could not produce craters on the workpiece surface any more when the pulse energy was reduced to a certain value. However, the condition of short pulse duration with high peak value still could produce clear craters on the workpiece surface. This indicates that a short pulse duration combined with a high peak value can generate better surface roughness, which cannot be achieved with long pulses. In the study, it was also found that reversed polarity machining with the appropriate pulse energy can improve the machined surface roughness somewhat better compared with normal polarity in finish machining, but some copper from the wire electrode is accreted on the machined surface.     

利用ANSYS的模具线切割加工表面变质层分析

分析了线切割(WEDM)加工表面变质层的影响因素,根据DK7732机床在模具加工中的应用,用有限元软件AN-SYS对线切割加工过程进行温度分布计算,在采用与真实加工相类似的边界条件下,模拟电参数(脉冲宽度)的变化对线切割加工工件表面变质层的影响,得出在实验条件下,按DK7732机床各档脉冲宽度加工时变质层的分布数据,以及其高温层和低温层区域相对较宽、中温区域很窄的结论,有利于后续的工艺探究。同时提出了减少变质层的相应措施。     

DK7732机床加工齿轮表面变质层分析

分析了线切割加工表面变质层的影响因素,在采用和真实加工相类似的边界条件下,用有限元软件ANSYS对线切割加工过程进行温度分布计算,模拟电参数(脉冲宽度)的变化对线切割加工齿轮工件表面变质层的影响,得出在实验条件下,按DK7732机床各档脉冲宽度加工齿轮时变质层的分布数据,以利于后续的工艺探究.同时提出了减少变质层的相应措施.     

电火花加工脉冲电源研究现状与发展趋势

脉冲电源是电火花加工的关键技术。文中针对传统电火花加工脉冲电源使用的缺点和局限性,介绍了当前电火花加工脉冲电源的研究现状和新的发展趋势,并对几种新型脉冲电源的研究和应用进行了分析。     

A magnetic-thyristor pulse generator for electric-discharge technologies

A generator is described that is intended for operation in the area of electric-discharge technologies. Depending on the electrical strength of the load, the generator produces voltages of up to 50 kV, the dissipated energy of the pulse is up to 200 J, and the pulse repetition rate is up to 100 Hz. The generator is based on the direct discharge of capacitors to a discharge gap through a coaxial cable with a length of up to 200 m and without additional switching components. The circuit stabilizing the pulse energy due to recuperation of the unused energy in the filter capacitor of the power supply is used to stabilize the energy dissipated by the load.     

An experimental investigation on machining parameters of AISI D2 steel using WEDM

The performance of the wire electrodischarge machining (WEDM) machining process largely depends upon the selection of the appropriate machining variables. Optimization is one of the techniques used in manufacturing sectors to arrive for the best manufacturing conditions, which are essential for industries toward manufacturing of quality products at lowest cost. As there are many process variables involved in the WEDM machining process, it is difficult to choose a proper combination of these process variables in order to maximize material removal rate and to minimize tool wear and surface roughness. The objective of the this work is to investigate the effects of process variables like pulse on time, pulse off time, peak current, servo voltage, and wire feed on material removal rate (MRR), surface roughness (SR), gap voltage, gap current, and cutting rate in the WEDM machining process. The experiment has been done using Taguchi’s orthogonal array L27 (3⁵). Each experiment was conducted under different conditions of input parameters and statistically evaluated the experimental data by analysis of variance (ANOVA) using MINITAB and Design Expert tools. The present work also aims to develop mathematical models for correlating the inter-relationships of various WEDM machining parameters and performance parameters of machining on AISI D2 steel material using response surface methodology (RSM).The significant machining parameters and the optimal combination levels of machining parameters associated with performance parameters were also drawn. The observed optimal process parameter settings based on composite desirability (61.4 %) are pulse on time 112.66 μs, pulse off time 45 μs, spark gap voltage 46.95 V, wire feed 2 mm/min, peak current of 99.99 A for achieving maximum MRR, gap current, gap voltage, cutting rate, and minimum SR; finally, the results were experimentally verified.