摘要
电火花加工(Electrical Discharge Machining,EDM)是一种通过电极和工件之间脉冲性火花放电,产生局部、瞬时的高温将金属材料逐步蚀除的非传统加工方法。目前已被广泛用于航空、航天、模具、刀具、精密仪器及微细加工等领域,已成为先进制造技术的一个重要分支。随着信息技术、网络技术、航空和航天技术、材料技术等高新技术的发展,电火花加工数控技术日益成熟。电火花加工数控系统源于传统切削加工数控系统,但由于加工过程的特殊性又不完全同于传统切削加工数控系统。本文基于PMAC(Programmable Multi-Axis Controller)构建了微细电火花成形加工运动控制系统,总结了运动控制系统的动态性能调试方法及微细电火花加工过程运动控制特点,针对PMAC构建的运动控制系统对微细电火花成形加工的影响进行研究。
首先,介绍了电火花加工的原理、机理和电火花加工机床的分类和组成,以及运动控制技术的系统组成、特点、应用及其分类。分析了微细电火花成形加工的特点及其对运动控制系统的要求。其次,根据PMAC运动控制器的特点,搭建了基于PMAC的微细电火花成形加工运动控制系统的硬件和软件体系,归纳总结了该系统的动态性能调试方法。
再次,分析总结了电火花加工过程运动控制特点。为了提高加工中运动控制的稳定性,减少冲击和加工误差,提出了基于速度静态规划的微细电火花成形加工运动控制策略,通过加工实验验证了控制策略的可行性和可靠性。
最后,分析讨论了微细电火花加工中运动参数和运动控制系统的动态性能对放电加工的影响,并得出了给定加工条件下的优化运动参数。实验表明基于PMAC的电火花成形加工运动控制系统不仅满足微细电火花加工对运动控制系统的要求,而且在加工的稳定性和加工效率方面有着显著的优势。
Electrical discharge machining (EDM) is one of the non-traditional machining processes. EDM is based on thermoelectric energy between the work piece and an electrode. A pulse discharge occurs in a small gap between the work piece and the electrode and removes the material from the work piece by melting and vaporizing. There are various types of products which can be produced using EDM such as dies, moulds, tools, parts of aerospace, automotive industry as well as micro components. With the development of internet technology, aerospace technology, material technology, numerical control (NC) for EDM become sophisticated increasingly. The NC for EDM is derived from other traditional NC for cutting, but different from it for distinctiveness during processing. In this paper, the motion control system of NC for micro sinking-die EDM based on programmable multi-axis controller (PMAC) is designed, the debugging methods of system and the characters of motion control are suggested, the study about effect of the motion control system of NC for micro die-sinking EDM based on PMAC is carried out.
Firstly, the principle and mechanism of EDM and the structure of various EDM are introduced. The system components, traits, application and classification of motion control are presented. The characters of micro EDM and its requirement to motion control are discussed.
Secondly, an overall design of the motion control system is taken after the PMAC’s hardware and software structure is introduced. According to the characters of PMAC, the software and hardware architecture of NC for micro sinking-die EDM based on PMAC are constructed. To improve dynamic performance, the debugging methods of motion control system are proposed.
Thirdly, the characters of motion control and its effect on machining are analyzed during machining. In order to improve stability of motion control and decrease geometric error and motion delay, a static velocity planning based motion control strategy of NC for micro sinking-die EDM is presented. Experiments show that the motion control strategy based on static velocity planning is feasible, stable and reliable.
Finally, the effects of machining motion and dynamic performance parameters on EDM are discussed. Given machining condition, the optimal motion parameters are presented. Motion control system based on PMAC is available for more precise position actuary, shorter response time and faster motion velocity. Experiments show that it not only meets demand of micro EDM to motion control system, but also has significant advantages to improve machining stability and efficiency. Multi-Axis Controller (PMAC)
引文
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