慢走丝电火花线切割粗加工仿真系统的开发

为对电火花线切割加工机理有更深刻的认识,了解加工参数对加工精度的影响规律,介绍了一个电火花线切割加工粗加工的仿真系统。仿真系统通过对放电点的探索、工件的去除以及对线电极丝振动的分析,将实际的加工现象形象地再现于计算机上。为证实仿真系统的正确性,将仿真结果与试验结果进行了比较。在试验结果的获取中,为能够得到很难测量的线电极周围的放电间隙和工件形状数据,提出一种新的三维形状测量方法。通过对仿真结果和试验结果的比较,定性地证明了仿真方法的正确性。研究结果表明:改变线电极张力及伺服电压值时,从仿真过程得到的加工形状结果与试验得到的加工形状结果其倾向基本一致;加工缝端部的形状呈凸形还是呈凹形,取决于加工过程中放电爆发力和静电引力的相对大小。

DEVELOPMENT OF SIMULATION SYSTEM ON WEDM FIRST CUT

In order to understand the mechanism of WEDM (Wire electrical discharge machining) and find out the influence of machining parameters on the accuracy, a simulation system for WEDM is developed., which can accurately reproduce the discharge phenomena of WEDM machining on computer through searching for the discharge location, removing the workpiece and analyzing wire vibration. To verify the feasibility of the simulation system, the simulation results are compared with the experimental results. In order to obtain the 3D data of the discharge gap and workpiece shape from the experimental results, a new measurement is proposed. By comparing the simulation results and experimental results, it is found that the simulation method is feasible. The results show that the machined shape obtained from the simulation is almost consistent with the machined shape obtained from the experiments when the wire tension and servo voltage are adjusted; whether the machined shape along machining direction is convex feature or concave feature depends on the relative value between the explosive force and electrostatic force.