微细线切割电极丝形位误差分析

Analysis of wire electrode shape and position error of MWEDM

为评估电极丝在微细电火花线切割加工过程中受到各种力作用下产生偏移量大小,利用有限元方法,首先求取电极丝仅受丝张力的总体刚度矩阵和电极丝仅受放电力的总体刚度矩阵,然后结合这两个刚度矩阵推导受丝张力和放电力合力的总体刚度矩阵,利用电极丝总体刚度矩阵求出电极丝最大变形解析式,并在此基础上分析了电极丝变形的影响因素.分析结果表明:提高电极丝的张力和电极丝的刚性以及减小导丝器之间的跨度都可以减小电极丝形位误差;提供微小能量的脉冲电源使偏移量达到最小是最佳的选择.

During the micro wire electrical discharge machining（MWEDM）,the micro wire electrode will deform under all kinds of force.A finite element analysis approach is presented for calculating the wire electrode deform.At first,the wire＇s stiffness matrix only by wire tension and that only by spark force were obtained independently,and then the total stiffness matrix and the wire max deform analytic expression were got and the influential factors were analyzed.The results show that the wire deformation can be reduced by increasing the wire tension and the wire rigidity,and decreasing the span between the guide pulleys,while providing the micro energy pulse power is the best choice.