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Development of Simulator for Wire Electrical Discharge Machining

线切割放电加工模拟器的研制

基本信息

批准号：
14350067
负责人：
KUNIEDA Masanori
金额：
$ 4.1万
依托单位：
Tokyo University of Agriculture and Technology
依托单位国家：
日本
项目类别：
Grant-in-Aid for Scientific Research (B)
财政年份：
2002
资助国家：
日本
起止时间：
2002 至 2003
项目状态：
已结题

来源：
https://kaken.nii.ac.jp/en/grant/KAKENHI-PROJECT-14350067/
关键词：
Wire electrical discharge machining Simulation of machining accuracy Wire electrode vibration Process reaction force Discharge delay time Material removal rate Pattern searching method Discharge location

项目摘要

In this research, we developed a WEDM (Wire Electrical Discharge Machining) simulation method which can reproduce the discharge phenomena of WEDM on computer accurately. The simulation process consists of searching for discharge locations, removing the workpiece and analyzing wire vibration. Since unclarified parameters such as ignition delay time, explosive force, damping coefficient, and permittivity of dielectric in simulation are difficult to measure from experiments, they were obtained by solving the reverse problem using parametric programming. With the parametric programming method, optimum parameters for simulation were searched simultaneously to minimize differences between simulation results and experimental results.In order to evaluate the simulation accuracy, simulation of finish cutting was performed using the parameters identified. It was found that high precision simulation of finish cutting can be realized with the simulation error less than 1.5μm.or the next step, simulation program for rough cutting was developed. Shapes of straight grooves and right angled grooves were cut, and then simulation results were compared with the experimental results. Changes in the straightness of both frontal and lateral surfaces of the grooves and the width of the grooves were investigated by increasing the feed rate and wire electrode tension. The results of simulation coincided qualitatively with the experimental results.

本研究发展了一种电火花线切割加工仿真方法，可以在计算机上准确再现电火花线切割加工的放电现象。仿真过程包括放电位置的搜索、工件的移除和焊丝振动分析。由于点火延迟时间、爆炸力、阻尼系数、电介质介电常数等参数在仿真中难以通过实验测量，因此采用参数化编程求解反问题得到这些参数。采用参数化编程方法，同时搜索最佳的仿真参数，以减小仿真结果与实验结果的差异，并利用所确定的参数进行精切削仿真，以评价仿真精度。结果表明，该方法可以实现精切削的高精度仿真，仿真误差小于1.5μm，并可进一步开发粗切削仿真程序。对直槽和直角槽进行了切削实验，并将仿真结果与实验结果进行了比较。通过增加进给速度和线电极张力，研究了槽的正面和侧面的直线度以及槽的宽度的变化。模拟结果与实验结果定性吻合。