Multi-discharge EDM coring of single crystal SiC ingot by electrostatic induction feeding method

A new technique of EDM coring of single crystal silicon carbide (SiC) ingot was proposed in this paper. Currently single crystal SiC devices are still of high cost due to the high cost of bulk crystal SiC material and the difficulty in the fabrication process of SiC. In the manufacturing process of SiC ingot/wafer, localized cracks or defects occasionally occur due to thermal or mechanical causes resulted from fabrication processes which may waste the whole piece of material. To save the part of ingot without defects and maximize the material utilization, the authors proposed EDM coring method to cut out a no defect ingot from a larger diameter ingot which has localized defects. A special experimental setup was developed for EDM coring of SiC ingot in this study and its feasibility and machining performance were investigated. Meanwhile, in order to improve the machining rate, a novel multi-discharge EDM coring method by electrostatic induction feeding was established, which can realize multiple discharges in single pulse duration. Experimental results make it clear that EDM coring of SiC ingot can be carried out stably using the developed experimental setup. Taking advantage of the newly developed multi-discharge EDM method, both the machining speed and surface integrity can be improved.     

展成式精密电火花加工机床

研制了一种展成式精密电火花加工机床，它含有3个回转机构和4个直线移动机构，工件苡轴，工具电极苡轴和转台均可按需要回转，坐标工作台可作纵向和横向移动，工件头架可作轴向和竖向移动。可设置成多种复合运动方式和相应的结构布局，具有很丰富的加工功能，加工精度能达到微米级并实现电火花镜面加工。     

High-efficiency finishing process for metal mold by large-area electron beam irradiation

A new finishing process for metal molds by large-area electron beam (EB) irradiation is proposed in this study. In the large-area EB irradiation equipment used here, an EB with high-energy density is irradiated without focusing the beam, and so the EB with a maximum diameter of 60 mm can be used for melting or evaporating metal surface instantly. Experimental results show that the surface roughness decreases from 6 μmRz to less than 1 μmRz in just a few minutes under proper machining conditions. The corrosion resistance of metal mold surface also could be greatly improved by large-area EB irradiation. Furthermore, the surface roughness of tilting surface close to 90° could be well improved. Therefore, large-area EB irradiation method has a possibility to become a high-efficiency finishing process for metal molds.     

Diffusion Bonded EDM Electrode with Micro Holes for Jetting Dielectric Liquid

This paper describes improvement of machining characteristics of electrical discharge machining of deep slots using a tool electrode which has micro holes for jetting dielectric liquid over the working surface. The tool electrode was made by the diffusion bonding of two copper plates, over an interface on which micro grooves for jetting the dielectric fluid were formed using electrolyte jet machining. In conventional machining, it is difficult to drill micro holes at the end of a slim electrode and circulate the dielectric fluid from the other end. Hence a solid tool electrode is used and periodically lifted up during machining to flush debris particles out of the discharge gap. Use of the newly developed tool electrode was found to shorten the processing time and improve machining accuracy significantly compared with the conventional solid tool electrode. Since the holes are micro, the outlet shapes are not replicated onto the bottom surface of the slot machined.     

微小电极夹持送进机构设计

设计实现了一种微小电极丝送进机构，使电极丝在随主轴旋转并在轴向高精度的伺服进给控制下，可实现电极丝长距离的送进及损耗自动补偿。其中电极丝的夹紧切换由一个常闭夹丝机构和一个常开夹丝机结构执行，常闭和常开夹丝机构可由电磁或形状记忆合金致动控制。     

从第14届国际电加工学术会议看电火花加工技术的发展趋势

结合第14届国际电加工学术会议和国内外电火花加工技术的最新进展，以一些最新的应用实例系统地综述了电火花加工技术的发展趋势。     

An investigation of ultrasonic-assisted electrical discharge machining in gas

This study focuses on using ultrasonic to improve the efficiency in electrical discharge machining (EDM) in gas medium. The new method is referred to as ultrasonic-assisted electrical discharge machining (UEDM). In the process of UEDM in gas, the tool electrode is a thin-walled pipe, the high-pressure gas medium is applied from inside, and the ultrasonic actuation is applied onto the workpiece. In our experiment, the workpiece material is AISI 1045 steel and the electrode material is copper. The experiment results indicate that (a) the Material Removal Rate (MRR) is increased with respect to the increase of the open voltage, the pulse duration, the amplitude of ultrasonic actuation, the discharge current, and the decrease of the wall thickness of electrode pipe; and (b) the surface roughness is increased with respect to the increase of the open voltage, the pulse duration, and the discharge current. Based on experimental results, a theoretical model to estimate the MRR and the surface roughness is developed.     

一种检测电火花加工间隙状态的柔性方法

介绍了一种在数控电火花加工脉冲电源中实现间隙状态检测的柔性方法，具有阈值设置柔性、状态识别准确的特点，巧妙地用一个稳压二极管的钳位作用提高了间隙状态识别的精度，非常适合需经常改变加工参数的加工实验使用。     

混粉电火花镜面加工技术及应用

利用自行研制的混粉电火花镜面加工装置，对混粉电火花镜面加工影响因素，加工表面性能等进行了深入研究，找出了粉末特性，工件材料，粉末浓度及放电参数等对混粉电火花镜面加工的影响规律，给出了合理的混粉电火花镜面加工工艺条件，以文中确定的加工工艺条件对铸造和压铸模具进行混粉电火花镜面加工，结果表明，该技术能提高模具制造质量，降低工人劳动强度，缩短模具制造周期。     

普通电火花成型机床加工小孔的改进方法

针对普通电火花成型机床在进行较深的小孔加工时存在的问题,对电火花成型机床进行部分改造,增加一个压力循环系统,使工具电极中喷出高压工作液,使之更适应小孔加工的条件.以DMKT132精密数控电火花成型机床的改造为实例,说明机床改造前后加工小孔的变化,结果表明,用该方法加工小孔,加工效率平均提高一倍以上,提高了加工质量,具有广泛的推广价值.