微小型电火花加工装置连续自动送丝的研究

针对电极夹持、更换困难,辅助加工时间长等问题,提出了在微小型电火花加工装置中实现连续自动送丝的方案,采用该方案不仅可提高加工效率,同时可以消除电极重新定位所带来的误差。系统地分析了超声马达定子的驱动原理,推导出了马达的振动方程。进行了电极驱动性能的测试和实验加工,验证了连续自动送丝方案的可行性。     

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。     

影响高速走丝电火花线切割丝损的因素与对策

分析了在高速走丝电火花线切割加工中出现的各种丝损现象，以及影响丝损现象的相关因素，提出了减少丝损的措施和对策，对进一步提高高速走丝电火花线切割的加工精度，减少电极丝的损耗．降低加工成本具有一定意义。     

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。     

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.     

新型中走丝线切割工作液的研制

根据中走丝电火花线切割加工的特点,研制出一种新型中走丝电火花线切割工作液。分析了中走丝电火花线切割工作液性能对加工的影响,探讨了工作液的组成和各种添加剂的选择。加工试验表明,研制的走丝电火花线切割工作液符合中走丝电火花线切割加工特性和防锈要求,能在高加工效率下加工得到较高表面质量的工件。     

电极丝损耗或断丝的预防对策

数控电火花线切割加工中 ,电极丝的损耗或断丝严重影响其连续自动操作的进行。尤其是在高速走丝电火花线切割中 ,因电极丝在加工中的反复使用 ,随着电极丝损耗的增加 ,切缝越来越窄 ,不仅会使加工面的尺寸误差增大 ;而且一旦在加工中发生断丝 ,加工必须重新开始 ,这不仅花费较多工时 ,而且影响加工的表面质量。电火花线切割加工中引起电极丝过量损耗断丝的原因有多方面 ,如电脉冲的稳定性、工艺参数的合理性、机械传动精度的高低、工件材料切割性能的优劣、切割路线与夹持方式的正确与否等 ,这些对于电极丝的使用寿命均有一定的影响。针对电…     

微细电火花加工技术的研究进展

研究和综述了微细电火花加工技术的研究现状和发展趋势。比较分析了常用微细加工与微细电火花加工方法的特点及应用，论述了线电极电火花磨削技术的原理及在微细加工中的作用。结合电火花加工过程中无宏观作用力的特点，论述了微细电火花加工装置微小型化的可行性和几种主要形式。     

电极丝横向振动对电火花线切割加工间隙影响规律研究

以提高电火花线切割加工效率为目的,分析了电火花线切割加工间隙对加工效率的影响,建立了电极丝横向振动数学模型,揭示了各工艺参数对电极丝振幅及加工间隙的影响规律。采用直径1mm的钼丝进行了加工实验,得到了峰值电流、脉冲宽度和脉冲频率等参数对电极丝振幅的影响规律。结果表明所建立的振动模型正确,可为优化电火花线切割加工间隙,从而提高其加工效率提供参考。     

介入治疗用导丝的电火花加工工装设计

通过分析介入治疗用导丝的材料特性和结构特点,确定了导丝加工采用电火花磨削加工方法;从提高导丝加工的质量、自动化程度和效率方面考虑,对加工工装的关键部件和控制系统进行了详细设计;最终设计了一套专用的导丝电火花加工工装,为介入治疗用导丝的加工探索出了一种新的方法.     

Review of size effects in micro electrical discharge machining

Electrical discharge machining (EDM) is one of the most promising non-traditional micro-scale machining methods. Because several operating parameters that are insignificant in macro EDM cannot be neglected during micro EDM process, models derived from the macro EDM process may be inappropriate at the micro scale. This paper contains a comprehensive review of size effects in traditional micro-machining and characteristics specific to micro EDM compared to macro EDM techniques. The very concept of size effects in micro EDM is thoroughly defined and three categories of effects are presented: material microstructure, processing parameter and thermal conduction size effects. Future potential research directions on the subject are also summarized. We assert that careful research and precise attention must be given to size effects in micro EDM. Size effect information especially benefits the machining speed and machining precision of micro EDM.     

影响电火花加工进程的因素分析

通过分析电火花加工机理,论述了电火花成型加工中电参数、工业速度、工作液、电极材料等主要过程影响因素,并探讨了EDM加工对工具钢的影响以及改善措施。     

Non-linear mechanism in electrical discharge machining process

Electrical discharge machining (EDM) is an advanced non-traditional manufacturing technology that has many advantages over other machining methods. Many papers have discussed the machining mechanism and modeling of the EDM process. However, previous mechanism models have mainly been linear, which contradicts their precondition that EDM is a stochastic process. In this paper, a non-linear mechanism model is proposed for the EDM process. A threshold condition that leads to chaos is calculated using the Melnikov theory. The theoretical results indicate that the EDM system can generate varied chaos in the evolution of electrical discharge. To verify this conclusion, validation experiments are implemented. Several sets of complete EDM processes’ real-time series are analyzed by multiple chaotic numerical criteria, including power spectrum analysis, principle component analysis (PCA), correlation dimension analysis, and Lyapunov exponent analysis. The experimental results provide further qualitative and quantitative evidence that a complete EDM process has dynamical chaotic characteristics.     

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.     

A fuzzy based decision model for nontraditional machining process selection

Manufacturing systems are processes in which inputs obtained from interior and exterior sources are transformed into an output by gathering inputs in an optimal way to guide the enterprises. Machining process plays a critical role in industry, and thus, directly affects the efficiency of the manufacturing systems. Due to different importance of the conflicting criterions, the multi-criteria decision-making methods are extremely useful in the selection process of the proper machining type. This study provides distinct systematic approaches in fuzzy and crisp environments to deal with the selection problem of proper machining process and proposes a decision support model for the guidance of decision makers to assess potentials of seven distinct nontraditional machining processes, namely laser beam machining, plasma arc machining, water jet machining, abrasive water jet machining, electrochemical machining, electrical discharge machining (EDM), and wire–EDM in the cutting process of carbon structural steel with the width of plate of 10 mm. The required data for decision and weight matrices are obtained via a questionnaire to specialists, as well as by deep discussions with experts and making use of past studies. Finally, an application of the proposed model is also performed via the SETED 1.0 software to show the applicability of the model.     

电火花加工内齿轮

介绍电火花加工内齿轮及其工艺,并对其中的技术难题和关键技术进行了分析.用此方法加工成本低,效率高,操作方便,产品质量稳定.     

Electrical discharge machining with ultralow discharge energy

The possibility of electrical discharge machining (EDM) with ultralow discharge energy has been investigated. EDM using an RC discharge circuit was performed at low open-circuit voltages and a capacitance of approximately 30 pF. Workpieces were ultrasonically vibrated to remove debris and bubbles from the discharge gap, thus preventing short-circuiting. The machining proceeded at voltages lower than 15 V at a vibration amplitude of 0.4 μm. The maximum discharge energy per pulse is as small as approximately 3 nJ under these conditions. The volumetric electrode wear ratio can be 0.2% at voltages lower than 40 V, while it is normally more than 1% for EDM using an RC discharge circuit. Workpiece surfaces processed at voltages of 20 V or lower are smooth and free of observable discharge craters, and show no typical features of surfaces machined by EDM.     

An experimental investigation into the micro-electrodischarge machining behavior of p-type silicon

The present study aims to investigate the feasibility of micro-structuring in p-type silicon, using conventional die-sinking electrodischarge machining (EDM). The EDM behavior of the silicon material is studied in terms of the effect of major operating parameters on the performance characteristics during the micro-hole machining. In addition, microelectrodes are fabricated successfully on the conventional EDM machine for machining different micro-structures in silicon. Three different types of micro-structures??micro-hole, blind slots, and through slots??are fabricated in p-type silicon successfully by using optimum parameters setting. It has been observed that p-type silicon is machinable by EDM using both the polarities. Moreover, like other electrodischarge machinable materials, the selection of optimum operating parameters is very important for improved performance, as those parameters are found to influence the EDM performance of silicon significantly. Finally, it has been concluded that p-type silicon is machinable into different forms of micro-structures by understanding its electrodischarge machining behavior and by careful selection of optimum parameters.     

加工圆锥滚子用导轮制导面倾角的探讨

采用无心贯穿磨削方法加工圆锥滚子外圆,导轮制导面倾角对加工的影响很大,探讨了导轮制导面倾角的设计,给出了公式。     

Monitoring of the electrical discharge machining process by abductive networks

The paper describes the use of abductive networks to monitor the electrical discharge machining (EDM) process. The voltage and current across the gap between the tool and workpiece are fed into the developed networks for the recognition of various pulse types in EDM in a winner-take-all fashion. Experimental results have shown that EDM pulses can be clearly classified even with different machining conditions. Hence, a reliable technique has been developed to monitor the EDM process.