Reverse Simulation of Sinking Electrical Discharge Machining

本研究旨在开发一种凹槽电火花加工的逆向模拟方法，该方法可以在考虑刀具电极磨损的情况下，获得能够精确加工所需工件形状的刀具电极形状。在所开发的反向模拟方法中，利用为正向模拟开发的放电位置搜索算法，使用与目标工件形状相同的初始形状的工件来加工工具电极。对实验得到的工具电极和工件的每脉冲去除体积数据进行了反向模拟切换。为了补偿曲率引起的误差，工具电极和工件的去除体积被除以分别与面对工具电极的单位面积的工件面积之比。实验结果表明，通过反向模拟得到的工具电极实际加工后的工件形状比通过与间隙宽度相等的距离偏移目标工件形状得到的工具电极形状更接近目标工件的形状。

This study aimed to develop a reverse simulation method for sinking electrical discharge machining(EDM) which can obtain tool electrode shapes with which desired workpiece shapes can be machined precisely taking into consideration tool electrode wear. In the reverse simulation method developed, the tool electrode is machined using a workpiece with the same initial shape as the target workpiece shape, applying the discharge location search algorithm developed for forward simulation. The data on the removal volumes of the tool electrode and workpiece per pulse, obtained from experiments, was switched in reverse simulation. To compensate for error due to curvature, the removal volumes of the tool electrode and workpiece were divided and multiplied by the ratio of the workpiece area facing a unit area of the tool electrode respectively. Experimental results showed that the workpiece shape after actual machining using the tool electrode obtained from reverse simulation was closer to the target workpiece shape than when the tool electrode shape was obtained by offsetting the target workpiece shape at a distance equal to the gap width.