【作者】 程化一；

【导师】 王晓光；

【作者基本信息】 武汉理工大学 ， 机械制造及其自动化， 2007， 硕士

【摘要】 随着科学技术的发展和社会进步，能够使用简单形状电极加工复杂形状工件电火花铣削加工，在20世纪90年代快速地发展起来。它解决了传统电火花成形加工技术因其工具电极制造繁杂所带来的加工灵活性差的难题。作为电火花铣削加工的一个重要的研究与应用方向——电火花套料加工技术，是使用紫铜线框电极作为工具电极，根据加工工件的形状，把它弯曲成相应的形状，在数控系统的控制下实施三维运动，从而加工出传统切削加工和电火花成形加工难以加工的工件，譬如采用电火花套料加工技术加工模具时，不需对型腔材料进行整体蚀除，就可以加工出模具的型腔，同时套料加工来出的型芯材料，还可以作为模具的型芯或派作其他的用途，从而有效地降低加工成本和提高加工速度。但是，这项工艺方法的基本机理尚不清楚、加工精度还不能确定，以及它的操作特性还不被了解。因此，分析放电模型或寻找套料加工的本质、推进套料加工的实用化，成为当今电火花套料加工研究的热点。为了弄清电火花套料加工的工艺参数与工艺结果的联系，本文首先利用科学的数理统计方法设计正交试验，对电火花套料加工进行实验，得出了在不同脉冲宽度、脉冲间隔、放电电流、放电时间等电参数配置条件下的电火花套料加工的工艺效果，有利于电火花套料加工工艺参数的选择与加工工艺的仿真。通过电火花套料加工模具的实验，证实了在普通数控电火花成形机床上采用电火花套料加工技术加工复杂异形工件的可行性，并且弄清了该技术的操作特性，解决了电火花套料加工模具或工件的部分难题，并将电火花套料加工技术应用于橡胶盒模具的制造中。为了更好地指导电火花套料加工，需要对其加工机理进行研究。本文运用MATLAB7.01中的人工神经网络模块，建立了电火花套料加工的工艺仿真模型。该工艺仿真模型能够正确地反映出电火花套料加工中，工艺效果与电规准参数的关系。因而，该模型可以在给定电参数的配置条件下，仿真出电火花套料加工的工艺效果，以及在指定套料加工工艺效果条件下，实现其电火花套料加工规准参数的优化选择。论文最后还分析了电火花套料加工的工艺仿真模型其预测误差为10％左右的原因。更多还原

【Abstract】 Companying the progress of society and the development of technology & science, the technology that EDMM1LL can machine complex workpieces with simple frame electrode has been developed rapidly in the 1990s. it solves the problems that the conventional EDM is lack of the flexibility in manufacture industry because of machining trouble of its electrode.EDM based on copper frame electrode is part of EDMMILL. Its electrode is made by the simple frame copper according to shape of workpieces; When the processing move is carried out by numerical control systems, the peripheral materials of the cavity is merely removed, so the EDM based on the copper frame electrode has faster rapidity、less cost、letter flexibility of machining workpieces than the conventional EDM with less removal of material in machining the cavity.More important and more advantageous, the new technology can machine the complex cavity, which the traditional mechanical machining and EDM craft can’t compete or are difficult to get, for example, the process of EDM can machine complex male die and cavity synchronously.But the basic mechanism of new EDM is unclear, manufacture accuracy is very difficult to get, and operational feature is not clarified. So finding the essence of the EDM、promoting the technology and craft to practice in the mechanical manufacture have become focus of the new EDM research at present. The following work has been accomplished in this dissertation.Firstly, in order to clarify the relationship of craft parameters and the machining craft results, such as machined surface roughness (SR), material removal rate (MRR) and tool wear rate (TWR), a lot of experiments are conducted , based on the orthogonal experimental design method on the EDM tool of precisely forming, where Pulse width, pulse interval, machining current, machining time are taken as the factors in orthogonal experiments. Further, the effects of the crucial electrical parameters on the craft results have been evaluated. So the data and analysis of experiments is advantageous to the choice of craft parameters and machining craft simulation in the same time.Secondly, through a lot of experiments of EDM on the regular EDM tools of precisely forming, the paper finds the operational characteristic of EDM based on copper frame electrode, proves the technological feasibility to machine the complex cavities. At last, the technology is used to machine the mould materials of rubber box, and some measures that help accomplish removal of its materials smoothly and successfully are taken up.Finally, in order to promote the development and application of the EDM craft better, it is necessary to research and make out the machining mechanism of EDM based on the copper frame, the paper utilizes both of MATLAB7.01 software and the artificial neural network to set up forecasting model of the craft effects for the EDM based on the copper frame, which can reflect the relationship between machining result and crucial electrical parameters. It is advantageous to choice of crucial electrical parameters under certain condition of the craft effects; Meanwhile, it is also possible to be used for the forecasting of the EDM craft effects according to the designated crucial electrical parameters. The reasons to arouse the forecasting error about 10% were analyzed.更多还原