Improving surface integrity and surface roughness by forming multi-discharging channels from one pulse in EDM
Improving surface integrity and surface roughness by forming multi-discharging channels from one pulse in EDM
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DOI：
10.1007/s00170-019-03373-2
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发表时间：
2019-02
期刊：
影响因子：
--
通讯作者：
Xin Mu;Ming Zhou;Qing Ye
中科院分区：
文献类型：
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作者：
Xin Mu;Ming Zhou;Qing Ye
传统的电火花加工通常需要较大的间隙距离才能获得完整的加工表面。然而，大的间隙距离确实阻碍了进一步提高表面质量，并且降低了加工效率。反之，本文采用小间隙放电，实现多放电通道同步放电。为此，本文研究了一种新的电火花加工自适应控制系统，以电弧比为控制指标，以间隙伺服电压为控制变量。通过调整间隙伺服电压，使电弧比跟随预定的电弧比期望值，从而使加工过程中不会产生电弧脉冲，从而获得加工表面的完整性。与常规电火花加工相比，该方法不仅获得了更完整的加工表面，而且表面粗糙度降低了近3.5倍，加工速度提高了2.5倍。此外，通过设定不同的燃弧比期望值，可以实现不同形式的一次脉冲多放电通道，满足不同的表面粗糙度要求。研究的意义在于，一次脉冲形成多放电通道为精密电火花加工提供了一种新的途径。
Conventional electrical discharge machining (EDM) usually took a large gap distance to obtain the integrity of machined surface. However, large gap distances really prevented further improving surface quality and lowered machining efficiency as well. Conversely, this paper took small gap distances in discharging so that discharging from multi-discharging channels could be synchronously realized. To this end, a new adaptive control system for EDM was studied in this paper where arcing ratio was chosen to be a control index and gap servo voltage was a control variable. Arcing ratio was forced to follow a predetermined arcing ratio expectation by adapting gap servo voltage so that arcing pulses could not take place in machining and thus the integrity of the machined surface can be obtained. Compared with conventional EDM, in addition to the more integrated machined surface had been obtained, the surface roughness had been lowered almost 3.5 times and the machining rate improved 2.5 times. Additionally, different forms of multi-discharging channels from one pulse were able to be realized by setting different arcing ratio expectations meeting different requirements of surface roughness. The significance of the study is that forming multi-discharging channels from one pulse displayed an innovative approach in precision EDM.