圆锥形端面电极定长补偿铣削加工建模与实验

Arithmetic and Experimental Study of Fix-length Compensation Based on Conical Bottom Shape of Electrode in EDM Milling

电火花铣削能利用简单电极有效地加工复杂三维形状。但由于加工中产生的电极损耗会对所加工型腔的几何精度产生很大的影响,所以必须对其进行有效的补偿。采用定长补偿方法进行电火花铣削加工时,旋转电极的端面会随着加工的进行逐步变成圆锥形且保持稳定,并在无轨迹重叠的铣削加工后产生锯齿状的加工面。为了得到平整的表面,对锯齿面的加工进行了研究,建立了基于圆锥形端面电极的定长补偿算法,通过实验分析了加工到达稳定状态时的波动和误差,实验结果与理论模型相吻合。最后通过加工实例证明了该方法的可行性。

Electrical discharge milling with a simple-shaped electrode is an effective machining method to fabricate complex three -dimensional structures. However,the serious electrode wear occurring in the machining process significantly deteriorates the geometrical accuracy of the products,so effective compensation method need to be conducted. Bottom shape of electrode will become conical under fix-length compensation method combined rotating tool electrode. After EDM milling in non-path overlapped manner,there is serrated surface remained. So this paper proposes the fix -length compensation method with conical bottom electrode,then do experiment and analyze fluctuation and error of the results respectively,the experimental results are very consistent with theoretical results. A demonstration cavity is machined with this compensation method. The effectiveness of this compensation method is verified.