A magnetic suspension spindle system for small and micro holes EDM
A magnetic suspension spindle system for small and micro holes EDM
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DOI：
10.1007/s00170-017-0990-x
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发表时间：
2018-02-01
影响因子：
3.4
通讯作者：
Feng, Yerui
中科院分区：
文献类型：
--
作者：
Guo, Yongfeng;Ling, Zebin;Feng, Yerui
由于传统伺服系统响应速度慢，在微小孔电火花加工中经常发生短路和电极弯曲等问题，降低了生产率和加工质量。为了解决这些问题，提出了一种磁悬浮主轴驱动方法。本文主要介绍了磁悬浮主轴驱动的原理、差距放电状态检测系统和主轴控制系统的硬件方案、检测和控制系统的软件设计、控制算法，并进行了对比实验。磁悬浮主轴性能测试结果表明，主轴轴向响应频率大于150 Hz，比传统滚珠丝杠伺服系统快。通过基于不同伺服系统或不同响应频率的对比实验，发现基于磁悬浮主轴驱动的微小孔电火花加工与传统的滚珠丝杠驱动相比，具有加工速度快、电极损耗小、加工精度高等优点（尺寸、形状、锥度和重铸层厚度）原因是随着轴向响应速度的增加，工作流体将加速碎片的去除和热能的传导，有利于消除短路现象，提高加工速度和加工质量。实验结果还表明，基于增量式比例积分微分（PID）算法的实时检测方法和变量积分的磁悬浮主轴系统比传统检测系统和滚珠丝杠伺服系统具有更好的性能。
Due to the slow response of the traditional servo system, short circuit and electrode bending often happen in small and micro holes electrical discharge machining (EDM); these issues usually reduce productivity and the machining quality. To address these issues, a magnetic suspension spindle drive method is proposed. The main object of this paper is to introduce the principle of magnetic suspension spindle drive, the hardware solution of the gap discharge state detection system and spindle control system, software design, and control algorithm of the detection and control systems, and the comparative experiments. Test results of the magnetic suspension spindle performance show that the axial response frequency was greater than 150 Hz, which was faster than that of traditional ball screw servo system. By means of the comparative experiments based on different servo system or different response frequency, it was found that compared with the traditional ball screw drive, small and micro holes EDM based on magnetic suspension spindle drive had the advantages of faster machining speed, less electrode loss, and better machining accuracy (size, shape, taper, and recast layer thickness) The reason is that with the increase of axial response speed, the removal of debris and conduction of heat energy would be speeded up by working fluid, and it would help to eliminate short circuit and improve machining speed and quality. The experimental results also demonstrate that the magnetic suspension spindle system based on the real-time detection method and variable integration of incremental proportional integration differentiation (PID) algorithm has better performance than that of the traditional detection system and ball screw servo system.