五轴联动电火花铣削加工技术研究
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摘要
电火花铣削加工是二十世纪九十年代发展起来的一种新型加工工艺。它具备放电加工不受工件材料强度、硬度、韧性等物理性能制约的特点,同时又具有机械加工利用多轴联动对工件进行铣削加工的特点。在航空制造业、模具加工业等领域应用前景十分广阔。
本文结合五轴联动电火花加工机床的研究与开发,以理论分析和工艺试验为基础,围绕电火花铣削加工的关键技术问题进行了探索性的研究。本文的主要研究工作如下:
(1)分析五轴电火花机床的结构布局,确定布局方案。对摆动机构和电极夹头进行结构设计,分别提出不同的设计方案,并对各方案进行比较,选择最优方案作为最终方案。
(2)根据圆柱形电极的损耗规律,建立了电极损耗的补偿模型,并进行与无补偿电火花铣削加工工件之间尺寸精度的对比实验。实验结果表明,本文提出的电极损耗补偿模型能够正确反映加工过程中电极的损耗状态,以补偿模型为依据进行损耗补偿的方法是可行的。
(3)针对放电加工的特殊性,研究了电火花铣削加工的数控编程技术。在所建补偿模型的基础上,提出了典型轮廓、平面型腔及曲面加工的电极运动轨迹算法。根据五轴联动电火花加工机床的结构,在所建立机床坐标系统的基础上求解该机床的运动学逆解,得到了该机床各个坐标轴驱动量的数学表达式。为机床数控系统自动编程软件的开发提供了重要的理论依据。
(4)总结了电火花铣削加工的工艺路线及电火花铣削加工工艺参数的选择原则,通过加工实验分析了加工精度和效率的影响因素,验证了所提出电极运动轨迹算法的正确性和UG CAM应用于电火花铣削的可行性。
Electrical Discharge Milling is a new kind of processing technology since 1990s. Electrical Discharge Milling has not only the characteristics of Electrical Discharge Machining which can not be restricted by physical properties of workpiece materials, such as strength, hardness, toughness, but the features of milling workpieces using multi axes synchronously. Therefore, Electrical Discharge Milling has wide prospect of application in aeronautical and astronautical manufacturing industry, mold machining industry and so on.
Based on the theoretical analysis and process experiments, the thesis investigates the key technical problems incorporating the research and development of five-axis linkage EDM machining tool. The main research contents are as follows:
(1) The structural layout scheme of five-axis EDM machine tool has been designated by analyzing movement function. The structures of the swing mechanism and the electrode holders are designed. Several designs are proposed and compared each other. Finally, the optimal scheme is selected as the final decision-making scheme.
(2) The compensating model with electrode wear is established on the basis of cylindrical electrode loss rule. The contrasting experiments of size precision are carried out between no-compensating and compensating EDM Milling. The experimental results indicate that the compensating model can reflect the electrode loss status accurately during processing and the compensating method of electrode wear proposed is feasible.
(3) Accounting for the particular properties of discharge machining, NC programming technology in EDM Milling is studied. On the basis of the compensating model presented, the thesis puts forward the path generating algorithm of the electrode movement on typical two-dimensional profile、plane pockets and surface machining. The solution of inverse kinematics of five-axis EDM machining tool is achieved based on the coordinates system of machine tool. The mathematical expression of driving value of each axis is deduced out, which provides an important theoretical foundation for developing automatic programming software for CNC system of EDM machining tool.
(4) The machining process route and the selecting principles of processing parameters in EDM Milling are summarized. Through the machining experiments, the influencing factors of machining accuracy and efficiency are analyzed, and the correctness of the algorithm on electrode movement path proposed and the feasibility of UG CAM application in EDM Milling are verified.
本文结合五轴联动电火花加工机床的研究与开发,以理论分析和工艺试验为基础,围绕电火花铣削加工的关键技术问题进行了探索性的研究。本文的主要研究工作如下:
(1)分析五轴电火花机床的结构布局,确定布局方案。对摆动机构和电极夹头进行结构设计,分别提出不同的设计方案,并对各方案进行比较,选择最优方案作为最终方案。
(2)根据圆柱形电极的损耗规律,建立了电极损耗的补偿模型,并进行与无补偿电火花铣削加工工件之间尺寸精度的对比实验。实验结果表明,本文提出的电极损耗补偿模型能够正确反映加工过程中电极的损耗状态,以补偿模型为依据进行损耗补偿的方法是可行的。
(3)针对放电加工的特殊性,研究了电火花铣削加工的数控编程技术。在所建补偿模型的基础上,提出了典型轮廓、平面型腔及曲面加工的电极运动轨迹算法。根据五轴联动电火花加工机床的结构,在所建立机床坐标系统的基础上求解该机床的运动学逆解,得到了该机床各个坐标轴驱动量的数学表达式。为机床数控系统自动编程软件的开发提供了重要的理论依据。
(4)总结了电火花铣削加工的工艺路线及电火花铣削加工工艺参数的选择原则,通过加工实验分析了加工精度和效率的影响因素,验证了所提出电极运动轨迹算法的正确性和UG CAM应用于电火花铣削的可行性。
Electrical Discharge Milling is a new kind of processing technology since 1990s. Electrical Discharge Milling has not only the characteristics of Electrical Discharge Machining which can not be restricted by physical properties of workpiece materials, such as strength, hardness, toughness, but the features of milling workpieces using multi axes synchronously. Therefore, Electrical Discharge Milling has wide prospect of application in aeronautical and astronautical manufacturing industry, mold machining industry and so on.
Based on the theoretical analysis and process experiments, the thesis investigates the key technical problems incorporating the research and development of five-axis linkage EDM machining tool. The main research contents are as follows:
(1) The structural layout scheme of five-axis EDM machine tool has been designated by analyzing movement function. The structures of the swing mechanism and the electrode holders are designed. Several designs are proposed and compared each other. Finally, the optimal scheme is selected as the final decision-making scheme.
(2) The compensating model with electrode wear is established on the basis of cylindrical electrode loss rule. The contrasting experiments of size precision are carried out between no-compensating and compensating EDM Milling. The experimental results indicate that the compensating model can reflect the electrode loss status accurately during processing and the compensating method of electrode wear proposed is feasible.
(3) Accounting for the particular properties of discharge machining, NC programming technology in EDM Milling is studied. On the basis of the compensating model presented, the thesis puts forward the path generating algorithm of the electrode movement on typical two-dimensional profile、plane pockets and surface machining. The solution of inverse kinematics of five-axis EDM machining tool is achieved based on the coordinates system of machine tool. The mathematical expression of driving value of each axis is deduced out, which provides an important theoretical foundation for developing automatic programming software for CNC system of EDM machining tool.
(4) The machining process route and the selecting principles of processing parameters in EDM Milling are summarized. Through the machining experiments, the influencing factors of machining accuracy and efficiency are analyzed, and the correctness of the algorithm on electrode movement path proposed and the feasibility of UG CAM application in EDM Milling are verified.
引文
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[36]Kruth J.P.,Lauwers B.,Clappert W..Study of EDM Pocketing[J].EDM Technology,1996(14):31-40
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[2]沈洪.电火花加工技术发展的里程碑——电火花铣床[J].电加工与模具,1994,(4):37-38
[3]叶军.电加工机床产品在激烈竞争中开拓发展[J].电加工与模具,2004,(1):1-5
[4]曹凤国,杨大勇,伏金娟.现代模具制造中的电火花加工技术[J].现代模具,2007,33:
[5]蔡兰,王霄.数控加工工艺学[M].北京:化学工业出版社,2004:236-237
[6]刘光壮,杨晓冬,迟关心,赵万生.电火花铣削加工技术及其发展状况[J].电加工,1998,(5):1-4
[7]K.Miyano.Generative Machining Method(EDM center)[J].Journal of Machine and Tool,1981,(3):86-93
[8]M.Suzuki,et al.An attempt of Electrodischarge Machining on a Machining Center[J].Proc.of ISEM=Ⅸ,Nagoya,1989:38-41
[9]K.Saito,et al.Development of Numerical Contouring Control Electric Discharge Machining (NCC-EDM)[J].Annuals of the CIRP,1986,Vol.35(1):117-120
[10]T.Kaneto,M.Tsuchiya,T.Fukushima.Improvement of 3D NC Contouring EDM Using Cylindrical Electrode[J].Proc.of ISEM=Ⅸ,Nagoya,1989:364-367
[11]刘光壮.基于分层去除制造的电火花铣削加工技术的研究.[D].哈尔滨:哈尔滨工业大学,1999:8-14
[12]T.Kaneto,M.Tsuchiya.Three-Dimensionally Numerically Controlled Contouring by Electrical Discharge Machining with Compensation for the Deformation of Cylindrical Tool Electrode[J].Precision Engineering,1998,Vol.10(3):157-163
[13]N.Mohri,M.Satio,M.Higashi.A New Process of Finish Machining on Free Surface by EDM Methods[J].Annals of the CIRP,1991,Vol.40(1):207-210
[14]N.Mohri,M.Suzuki,M.Furuya,K.Saito.Electrode Wear Process in Electrical Discharge Machining[J].Annals of the CIRP,1995,Vol.44(1):165-168
[15]Masanori Kunieda,Masahiro Yoshida.Electrical Discharge Machining in Gas[J].Annals of the CIRP,1997,Vol.46(1):143-146
[16]赵万生,王振龙等.国外特种加工技术的最新进展[J].电加工,1999(5):12-19
[17]徐盛林.日本电火花加工技术的发展现状[J].电加工,2001(3):13-16
[18]狄士春,王振龙等.电极等损耗微细电火花加工技术[J].电加工,1998(2):1-3
[19]M.Fujino,N.Okamoto,T.Masuzawa.Development of Multi-Purpose Microprocessing Machine[J].Proc.Of ISEM=Ⅺ,Lausanne,1995:2-8
[20]Zuyuan Yu,Takahisa Masuzawa,Masatoshi Fujino.3D Micro-EDM with Simply Shaped Electrode[J].Annals of the CIRP,1997,Vol.46(1):1-8
[21]Zuyuan Yu.Three Dimensional Micro-EDM Using Simple Electrodes.[D].Tokyo:University of Tokyo,1997:54-62
[22]T.Yuzawa,T.Magara,et al.Micro Contour EDM Machining Using Thin Cylindrical Electrode[J].Denki Kako Gijutsu,1995,Vol.19(63):1-6
[23]M.Bayramoglu,A.W.Duffill.Systematic Investigation on the Use of Cylindrical Tools for the Production of 3D Complex Shapes on CNC EDM Machines[J].Int.J.Mach.Tools Manufact,1994,Vol.34(3):327-339
[24]M.Bayramoglu,A.W.Duffil.Production of 3-D Shapes Using Computational Electrodischarge Machining[J].Proc.of 29th Int.M.T.D.R.Conf.,London,1992:107-112
[25]Kruth J.P.,Lauwers B.,Clappert W..A Study of EDM Pocketing[J].Proc.of ISEM-X,Magdeburg,1992:121-135
[26]Songlin Ding,Ridong Jiang.Tool path generation for 4-axis contour EDM rough machining[J].Int.J.Machine Tools & Manufacture,2004(44):1493-1502
[27]衣建刚,刘正埙.电火花数控仿铣加工成形规律的研究[J].电加工,1998(3):11-12
[28]周勇,刘正埙.基于AutoCAD的电火花仿铣加工CAD/CAM系统[J].航空精密制造技术,2000(1):37-39
[29]贠敏、于源、王小椿.基于混合八叉树模型的电火花数控加工仿真研究[J].组合机床与自动化加工技术,2001(9):9-12
[30]贠敏、于源、王小椿.模拟退火算法在电火花创成加工中的应用[J].电加工,2001(4):20-23
[31]伍瑞阳.数控电火花加工实用技术[M].北京:机械工业出版社,2007:36,67
[32]黄玉美.数控机床总体方案的创新设计[J].世界制造技术与装备市场,2001(1):41-43
[33]张广鹏,黄玉美,苏菊宁,李艳.基于解析方法的机床运动创成[J].西安理工大学学报,1998,Vol.14(3):242-246
[34]曹凤国.电火花加工技术[M].北京:化学工业出版社,2005:79,3
[35]王振龙.微细加工技术[M].北京:国防工业出版社,2005:77-117
[36]Kruth J.P.,Lauwers B.,Clappert W..Study of EDM Pocketing[J].EDM Technology,1996(14):31-40
[37]卢存伟.电火花加工工艺学[M].北京:国防工业出版社,1988:77
[38]《金属切削理论与实践》编委会.电火花加工[M].北京:北京出版社,1980:79-94
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