基于LabVIEW的电火花线切割放电加工状态的研究

电火花线切割加工时放电加工状态决定着加工的质量和速度,电极丝和工件之间的放电电压是对放电加工过程进行实时检测的重要参数.以LabVIEW为开发平台,以放电电压为检测参数,构建了电火花线切割放电加工状态识别仿真系统.该系统主要包括线切割放电状态识别模块、BP神经网络放电预测模块以及加工稳定性分析模块,对提高电火花线切割加工质量、加工效率及智能化加工有良好的效果.     

气中高速走丝电火花线切割放电状态的研究

气中电火花线切割加工是电火花线切割精加工的发展趋势.因此对气中电火花放电状态的检测是电火花线切割加工过程中极为重要的一个环节,文中介绍了利用放电状态时不同的电压波形对放电状态进行区分并分析了它们的特点.     

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,     

基于统计分析的电火花线切割加工稳定性研究

研制了电火花线切割加工间隙放电状态检测系统,并运用时序分析理论中的统计检验的方法对加工中由正常放电相对时间比率值构成的时间序列进行了分析,指出了电火花线切割加工稳定时的正常放电相对时间比率值构成的时间序列的统计特征。提出用量纲一波形参数——峰度值（峭度系数）来判断电火花线切割加工的稳定性,用试验的方法研究了该方法的可靠性,为采取适当的电参数控制策略,提高加工稳定性提供了重要的依据。     

工程陶瓷材料电火花线切割加工的机理研究

针对如何提高工程陶瓷材料加工质量这一问题,对碳化硼工程陶瓷进行了电火花线切割加工的试验研究.介绍了工程陶瓷材料的电火花放电加工原理,通过对碳化硼工程陶瓷进行的电火花线切割加工工艺试验,探讨了电参数对工程陶瓷电火花线切割加工表面质量的影响规律.该研究对进一步深化电火花加工技术的基础理论,促进该技术在实际生产中的推广应用具有重要意义.     

递推识别检测法实现往复走丝型电火花线切割机床的自适应控制

往复走丝型电火仡线切割机床是我国独有的放电加工特种设备,由于其走丝系统的特殊性,其放电机理有别于其他放电加工机床。而随着技术的发展,特别是数控技术的日新月异,自适应控制技术在电加工机床领域广泛应用。但是,对于往复走丝型电火花线切割机床的控制系统而言,由于其加工放电状态稳定性很差,     

基于模糊控制的微细电火花加工脉冲电源研究

设计了一套微细电火花加工脉冲电源,该电源采用有效放电火花数检测方法对放电状态进行统计,并利用模糊控制算法对脉冲宽度和脉冲间隔进行调整以改善加工性能。试验结果表明,该脉冲电源在保证加工稳定性的基础上,能够有效地提高加工精度及加工效率。     

电火花线切割加工工艺的特点

1 引言 线切割加工是电火花线切割加工的简称,是用线状电极(钼丝或钨丝)靠电火花放电来对工件进行切割.     

压电自适应微细电火花加工系统特性分析

针对微细电火花加工过程中排屑困难,极易产生短路、拉弧等非正常加工现象,进而造成微细电火花加工效率低、电极损耗大等特点,基于压电陶瓷的逆压电效应提出了一种新的加工方法--压电自适应微细电火花加工技术,对其加工原理进行了详细阐述,并结合试验对该加工系统的加工特性进行了详细分析.试验证明该技术在加工过程中能够实现放电间隙与放电状态的自适应调节,促进捧屑,可有效控制短路及拉弧现象的出现,进而提高微细电火花的加工稳定性及加工效率,并能实现超低电压下的微细电火花加工.结合实例说明采用压电自适应微细电火花加工技术进行小孔加工的过程中能实现稳定加工,获得较高的加工效率,并且加工的小孔圆度较好,说明该技术在微小孔加工方面具有广阔的应用前景.     

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.     

Development of parallel spark electrical discharge machining

This paper describes the development of parallel spark EDM method. In the discharge circuit, the electrode is divided into multiple electrodes, each of which is electrically insulated and connected to the pulse generator through a diode. A capacitor is inserted parallel to each discharge gap between each electrode and workpiece (here workpiece is common for each electrode). Compared with conventional EDM in which only a singular discharge can be generated for each pulse, multiple discharges can dispersively be generated for each pulse in parallel spark EDM. Results of experiments on parallel spark EDM and conventional EDM show that not only is the machining process more stable, but the machining speed and surface roughness can also be improved with parallel spark EDM.     

提高模具电火花加工切割形状精度的途径

电火花线切割是模具零件的主要加工方式。模具加工精度包括表面粗糙度、形状位置精度和尺寸精度,慢走丝线切割难以控制表面粗糙度和形状精度。影响数控电火花线切割加工精度的因素主要有偏移量、取件位置、切割路线、起点、装夹与定位及引入、切出、超切、回退程序等。通过进行合理的工艺分析,正确计算数控编程中电极丝的设计走丝轨迹,可确保模具的加工精度。通过确定穿丝孔和优化切割路线来改善切割工艺,是提高模具型腔切割质量和生产效率的一条行之有效的重要途径。     

数控电火花成型机的自适应控制技术研究

针对数控电火花成型机中电火花加工间隙放电过程难以控制的问题,提出基于电火花加工间隙状态的识别和合理的伺服进给系统的电火花自适应控制技术。通过正确的间隙检测方法,配以专家系统和决策控制软件,保证数控电火花成型机的工作可靠和安全,并使长期无人控制操作成为可能,从而为数控电火花成型机的自适应控制技术研究提供了理论依据。     

Optimization of wire electrical discharge machining (WEDM) process parameters using Taguchi method

Wire electrical discharge machining (WEDM) is extensively used in machining of conductive materials when precision is of prime importance. Rough cutting operation in WEDM is treated as a challenging one because improvement of more than one machining performance measures viz. metal removal rate (MRR), surface finish (SF) and cutting width (kerf) are sought to obtain a precision work. Using Taguchi’s parameter design, significant machining parameters affecting the performance measures are identified as discharge current, pulse duration, pulse frequency, wire speed, wire tension, and dielectric flow. It has been observed that a combination of factors for optimization of each performance measure is different. In this study, the relationship between control factors and responses like MRR, SF and kerf are established by means of nonlinear regression analysis, resulting in a valid mathematical model. Finally, genetic algorithm, a popular evolutionary approach, is employed to optimize the wire electrical discharge machining process with multiple objectives. The study demonstrates that the WEDM process parameters can be adjusted to achieve better metal removal rate, surface finish and cutting width simultaneously.     

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.     

Simple spark erosion device based on optical disk or hard disk drive actuators

We present the design of a compact electric discharge device incorporating hard disk or optical disk drive actuators. It is simple enough to be assembled in the absence of a mechanical workshop. The electronic circuit allows the adjustment of current, voltage, and discharge power. The system has been tested with organic dielectric liquids and deionized water and spark conditions; dynamic properties and machining characteristics were investigated. This device can be used to shape materials or to produce powdered samples with low material loss and minimal liquid consumption.     

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.     

复合运丝型电火花线切割加工参数分析与研究

提出了一种新型电火花线切割机床,即电极丝作往复直线运动的同时还绕自身轴线高速旋转的复合运丝型线切割机床。介绍了该类机床与其他线切割机床加工的基本工艺指标。通过与高速走丝电火花线切割机床比较实验,分析了脉冲宽度、脉冲间隔、脉冲峰值电流等电参数对加工工艺指标的影响,实验表明这种独特的复合运丝方式在降低表面粗糙度、提高加工精度等方面较传统运丝方式具有较大的优越性,且机床结构较为简单,对于各种工艺参数和电参数具有更加广泛的适用性,具有进一步研究和推广价值。     

一种基于模糊神经网络确定电火花加工条件的新方法

在电火花加工中,影响因素较多,难以确定最优加工条件。应用模糊神经网络确定电火花加工条件是一种新的尝试,它可以充分发挥模糊逻辑和神经网络的长处。为方便操作者决定粗加工最优加工条件,并提高表面加工效果和粗加工速度,本文提出了一种基于模糊神经网络自动确定和优化电火花成形加工中加工参数的方法。经实践证明,用该方法所确定的最优加工条件,能保证较高的粗加工速度,方便了操作者对加工条件的确定。     

往复走丝电火花线切割高效低损耗切割研究

目前,高速往复走丝电火花线切割最高切割效率已突破200mm2/min,传统脉冲电源靠单纯提高脉冲能量来增加切割效率会导致钼丝损伤大、损耗加剧,短时间内就可能出现断丝。从脉冲电源的放电波形分析入手,分析了传统脉冲电源和高效低损耗脉冲电源的差异。研究认为,采用阶梯脉冲合理控制放电电流的前后沿,在加工中对非正常放电脉冲及时切断以减小对电极丝造成的损伤及损耗,采用等能量脉冲方式提高放电利用率等措施能大大提高切割效率,改善切割表面粗糙度,在切割效率190～200mm2/min条件下能实现长期稳定切割。