微细电火花加工的底面轮廓模型及定长补偿方法

Bottom Surface Profile of Single Slot and Fix-Length Compensation Method in Micro-EDM Process

针对三维金属微细结构的微细电火花加工,应用等损耗理论,采用分层加工的方法,建立了单道加工时底面形状随电极损耗而变化的轮廓模型。在此基础上,提出定长补偿的方法,给出了补偿长度的计算公式。对底面轮廓模型及定长补偿方法进行了仿真分析。实验测定了微细条件下钨打钢的相对体积损耗比,进行了无补偿和定长补偿的实验加工。仿真及实验结果表明无补偿时底面轮廓为一指数曲线,与实验结果相符;定长补偿方法加工出的底面轮廓为一幅值恒定的波动曲线;随着补偿精度le的增大,底面轮廓的波动范围也越大;在符合端面损耗理论的范围内,分层厚度越大,加工相对误差越小;定长补偿方法提高了加工尺寸精度和形状精度,补偿方法可行。

In this paper, bottom surface profile algorithm without compensation is deduced firstly based on laminated machining approach and uniform wear method. Then fix-length compensation process is proposed, and its algorithm is given. Using this proposed approach, simulations of the bottom surface profile were performed. According to the simulation of fix-length compensation interesting conclusions are made. Series experiments of micro slot confirm the proposed process and the algorithm.