Development, analysis and application of an actuated variable tool electrode for die-sinking EDM - VariSink4EDM

沉模电火花加工(EDM)是德国工具和模具制造行业中应用最多的制造工艺之一。通常需要设计复杂的工具电极，通过昂贵且耗时的加工来制造。因此，电极制造和机器设置的时间曝光量通常高于电火花加工过程。在此基础上，提出了一种新颖的电火花粗加工工具电极概念，并将其应用于本项目中。该研究项目的主要目的是提供有关在电火花加工过程中使用捆绑式和可变可调单电极工具段的基本知识。这就需要开发、实施和分析一种新颖的、高度创新的驱动可变工具电极。这一概念包含了25个方形杆段的捆绑，这些杆段可以通过摩擦锁定的单执行器单独移动。因此，驱动段可以形成所需的3D形状，同时避免了额外的加工和机床设置。当使用芯片下沉电极时，所选分段的倒角实现了内冲洗的优势。由于执行机构的概念，可以探索新的冲洗策略。对捆绑工具段工具电极的材料和工艺行为进行了实验研究。还将开发与之配套的、横截面一致的直线直驱。它们不仅提供每个刀具段之前的单独定位和过程中的磨损补偿，而且还能够执行段的高频运动，以实现新的冲洗策略。应利用电火花加工过程的电容行为来开发优化的过程控制。这是基于自感知估计方法，利用该方法可以在现场设置具有固有磨损补偿的优化工作间隙，以及自动启动冲洗过程。在第一个资助期结束时，一种创新的可变可执行工具电极可用于电火花加工的粗加工作业，并实施了一种新的冲洗概念。

Die-sinking Electrical Discharge Machining (EDM) is one of the most applied manufacturing processes in the German tool- and mould-making industry. Complex designed tool electrodes, manufactured by costly and time-consuming machining, are often required. As a result, the time exposure for manufacturing of electrodes and machine setup is often higher than for the EDM process. Based on the state of the art, an innovative tool electrode concept for roughing in EDM has been derived, which should be implemented in this project. The main objective of the research project is to provide basic knowledge on the use of bundled and variably adjustable single electrode tool segments in the EDM process. This requires the development, implementation and analysis of a novel, highly innovative actuated variable tool electrode. The concept contains the bundling of 25 square rod segments that can be shifted individually by friction-locked single actuators. Therefore, the actuated segments can form a needed 3D shape while additional machining and machine setup is avoided. The chamfering of selected segments enables the advantage of inner flushing when using die-sinking electrodes. Due to the actuating concept, novel flushing strategies can be explored. Experiments will be conducted to study the material and process behavior of the bundled tool segments tool electrode. Accompanying, cross section conformable linear direct drives will be developed. These not only provide the individual positioning of each tool segment before and wear compensation during the process, but are also able to execute a high-frequency motion of the segments for the realization of the new flushing strategies. The capacitive behavior of the EDM process should be used to develop an optimized process control. This is based on self-sensing estimation methods, with which in-situ an optimized working gap with inherent wear compensation can be set, as well as an automated initiation of the flushing process. At the end of the first funding period, an innovative and variable actuable tool electrode is available for roughing operations with die-sinking EDM and a novel flushing concept is implemented.