CN104646774A - Electrode loss real-time compensation method based on spark discharge rate - Google Patents
Electrode loss real-time compensation method based on spark discharge rate Download PDFInfo
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- CN104646774A CN104646774A CN201410777505.9A CN201410777505A CN104646774A CN 104646774 A CN104646774 A CN 104646774A CN 201410777505 A CN201410777505 A CN 201410777505A CN 104646774 A CN104646774 A CN 104646774A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23H—WORKING OF METAL BY THE ACTION OF A HIGH CONCENTRATION OF ELECTRIC CURRENT ON A WORKPIECE USING AN ELECTRODE WHICH TAKES THE PLACE OF A TOOL; SUCH WORKING COMBINED WITH OTHER FORMS OF WORKING OF METAL
- B23H1/00—Electrical discharge machining, i.e. removing metal with a series of rapidly recurring electrical discharges between an electrode and a workpiece in the presence of a fluid dielectric
- B23H1/02—Electric circuits specially adapted therefor, e.g. power supply, control, preventing short circuits or other abnormal discharges
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23H—WORKING OF METAL BY THE ACTION OF A HIGH CONCENTRATION OF ELECTRIC CURRENT ON A WORKPIECE USING AN ELECTRODE WHICH TAKES THE PLACE OF A TOOL; SUCH WORKING COMBINED WITH OTHER FORMS OF WORKING OF METAL
- B23H1/00—Electrical discharge machining, i.e. removing metal with a series of rapidly recurring electrical discharges between an electrode and a workpiece in the presence of a fluid dielectric
- B23H1/04—Electrodes specially adapted therefor or their manufacture
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- G—PHYSICS
- G16—INFORMATION AND COMMUNICATION TECHNOLOGY [ICT] SPECIALLY ADAPTED FOR SPECIFIC APPLICATION FIELDS
- G16Z—INFORMATION AND COMMUNICATION TECHNOLOGY [ICT] SPECIALLY ADAPTED FOR SPECIFIC APPLICATION FIELDS, NOT OTHERWISE PROVIDED FOR
- G16Z99/00—Subject matter not provided for in other main groups of this subclass
Abstract
An electrode loss real-time compensation method based on a spark discharge rate relates to a method for compensating electrode loss in real time in an electric spark milling machining process, solving the problems of an existing electric spark milling machining process that the electrode loss is not accurate so that the machining precision requirement cannot be met and servo feeding is not stable so that the machining efficiency is low. The method comprises the following steps: step 1: collecting a voltage value between electrodes in real time, and judging whether discharge occurs or not according to the voltage value between the electrodes; when the discharge occurs between the electrodes, counting the discharge rate in an electric spark milling discharging process to obtain w(te); step 2: calculating a real-time electrode loss rate eta (te) according to a relation formula of the discharge rate and the electrode loss rate; and step 3: adjusting an electrode loss compensation amount by an electrode movement system according to the electrode loss rate eta (te) calculated by the step 2, so as to realize the aim of adjusting the electrode loss compensation according to the discharge rate between the electrodes. The electrode loss real-time compensation method is mainly used for the field of electric spark machining.
Description
Technical field
The present invention relates to the method for export license real-Time Compensation in a kind of electrical discharge milling machining.
Background technology
Employ a large amount of high strength, exotic material in aerospace industries as titanium alloy, Ni-based high-temperature alloy etc., with traditional processing method to difficult-to-machine material carry out large volume material remove time the cost of charp tool very high.Electrical discharge milling machining utilizes digital control system to control simple tubulose electrode movement, and be equipped with high pressure and rush liquid, achieve the electric spark layered milling processing being similar to traditional Milling Process, its current working (machining) efficiency has also reached the level close with mechanical milling, therefore has very large application space in field of aerospace.The compound action of the heat relying on interpolar discharge to produce due to electric spark milling removes material, and the while that workpiece material being removed, electrode has also been depleted a part, therefore in process electrode in the axial direction length shorten gradually, affect machining accuracy.The precision of compensation for electrode wear directly decides machining accuracy, and therefore compensation for electrode wear problem is one of key technology realizing electrical discharge milling machining.
Current compensation for electrode wear method mainly contains off-line predictive compensation method, on-line checkingi penalty method and online interval Fixed-point tool setting penalty method.Off-line predictive compensation method mainly experimentally experience or mathematical operation export license is predicted, but it is larger to carry out pre-time determination error to the machined parameters of the unknown.The method that on-line checkingi penalty method mainly uses the method detecting electrode length such as probe or CCD video imaging to compensate, its implementation procedure is very loaded down with trivial details and need checkout equipment.Online interval Fixed-point tool setting penalty method is by adding breaking working control electrode uses electric spark to contact perceptional function detecting electrode length variations to fixing point in man-hour, thus by the compensation for electrode wear of measurement in ensuing procedure, this compensation method needs to spend the more time, reduce working (machining) efficiency, and be that the export license amount of the preceding paragraph program is compensated in next section of program, precision is not too high.
Publication number is the Chinese invention patent application of 101982280A is calculate export license amount according to discharge energy, although what it adopted is called real-Time Compensation, but be actually during the waste disposable compensation calculated according to discharge energy in certain hour is processed to next section, this compensation is not in real time real real-Time Compensation, and export license amount and electrode wear rate have the difference of essence.
Therefore, research and develop a kind of simple, reliable, practical compensation for electrode wear method and become key electric spark milling being applied to difficult-to-machine material manufacture field.
Summary of the invention
The present invention cannot meet requirement on machining accuracy and the unstable problem causing working (machining) efficiency low of servo feed to solve inaccurate the causing of compensation for electrode wear in existing current electrical discharge milling machining, the invention provides a kind of export license real-time compensation method based on spark discharge rate.
Based on an export license real-time compensation method for spark discharge rate, it is characterized in that, the method comprises the steps:
Step one: Real-time Collection voltage across poles value, and judge whether interpolar discharges according to voltage across poles value, when electric discharge occurs interpolar, statistics is carried out to the discharge rate in electric spark milling discharge process and obtains:
T
efor the discharge time in the single pulse time; T is the sampling time; W (t
e) be discharge rate;
Step 2: the relation formula according to discharge rate and electrode wear rate calculates real-time electrode wear rate η (t
e), described according to the relation formula of discharge rate and electrode wear rate is:
η(t
e)＝f(t
e)*w(t
e)，
F (t
e) be the relationship between discharge rate and electrode wear rate; η (t
e) be electrode wear rate,
Step 3: electrode movement control system calculates the electrode obtained proportion of goods damageds η (t according to step 2
e) regulate compensation for electrode wear amount, thus reach the object that compensation for electrode wear carries out according to interpolar discharge rate adjusting in real time.
The method that the application proposes and existing energy compensating export license method have the difference of essence:
(1) based on detection method different: existing energy compensating export license method is by detecting discharge power or current signal calculates discharge energy; And the application calculates spark discharge rate by detecting the real-time discharge voltage of interpolar;
(2) computational methods compensated are different: existing energy compensating export license method calculates export license amount according to discharge energy; And the application calculates according to spark discharge rate is electrode wear rate, electrode wear rate and export license amount are by the difference of essence.
(3) mode compensated is different: although existing energy compensating export license method is called real-Time Compensation, is actually in being processed to next section by the waste disposable compensation calculated according to discharge energy in certain hour; And the application calculates the electrode obtained proportion of goods damageds according to discharge rate, export license is evenly distributed in processed distance, as long as there is spark discharge will there is real-time compensation for electrode wear, and the numerical value of the just electrode wear rate that the application adjusts according to discharge rate.
Principle of the present invention is:
In electrical discharge milling machining process, in real time interpolar discharge voltage waveform is detected, and records real-time voltage across poles numerical value,
When voltage across poles is greater than certain numerical value, interpolar does not discharge, and interpolar is in Light Condition,
When voltage across poles is less than short circuit reference voltage, interpolar is short-circuited,
Only have when voltage across poles value is between zero load and short circuit reference voltage level, interpolar is discharging.
The method that the present invention proposes only just carries out the real-Time Compensation of export license when spark discharge; The compensation of export license is not carried out time unloaded; During short circuit, processing is interrupted, and electrode is carrying out a cutter lifting action perpendicular to direction of feed, and electrode wear rate now calculates by the maximum of spark discharge rate.
When electric spark regular picture, the spark discharge rate in the sampling period is calculated according to the voltage across poles detected in real time, and real-time spark rate is converted to corresponding electrode wear rate by the formula drawn early stage, and then adjust compensation for electrode wear amount in real time, realize accurate loss balancing.
Based on above principle, the real-time compensation for electrode wear method based on spark discharge rate that the present invention proposes, achieve when only having electric spark milling to discharge and just compensate, and achieve the function that compensation rate carries out according to spark discharge rate adjusting in real time, greatly improve the precision of compensation for electrode wear, overcome the problem that servo feed instability causes working (machining) efficiency low.
Accompanying drawing explanation
Fig. 1 is the principle schematic of a kind of export license real-time compensation method based on spark discharge rate of the present invention;
Fig. 2 is the relation schematic diagram of spark discharge rate and electrode wear rate; Wherein, A represents low bloom, and B represents high bloom, and Reference numeral 1 represents unloaded place, and C represents shorting region;
Fig. 3 is the interpolar regular picture voltage waveform view gathered; Wherein U represents voltage across poles value.
Detailed description of the invention
Detailed description of the invention one: present embodiment is described see Fig. 1, a kind of export license real-time compensation method based on spark discharge rate described in present embodiment, the method comprises the steps:
Step one: Real-time Collection voltage across poles value, and judge whether interpolar discharges according to voltage across poles value, when electric discharge occurs interpolar, statistics is carried out to the discharge rate in electric spark milling discharge process and obtains:
T
efor the discharge time in the single pulse time; T is the sampling time; W (t
e) be discharge rate;
Step 2: the relation formula according to discharge rate and electrode wear rate calculates real-time electrode wear rate η (t
e), described according to the relation formula of discharge rate and electrode wear rate is:
η(t
e)＝f(t
e)*w(t
e)，
F (t
e) be the relationship between discharge rate and electrode wear rate; η (t
e) be electrode wear rate,
Step 3: electrode movement control system calculates the electrode obtained proportion of goods damageds η (t according to step 2
e) regulate compensation for electrode wear amount, thus reach the object that compensation for electrode wear carries out according to interpolar discharge rate adjusting in real time.
In present embodiment,
, because the turbine disk needs the curved surface more complicated of processing, there is many electrode skies and walk stroke, the superiority of the export license real-time compensation method based on discharge rate can be demonstrated in embodiment: when adopting the electrical discharge milling machining high-temperature alloy turbine disk.Electrode when turbine disk surface of the work carries out feed according to procedure prepared in advance,
When electrode and workpiece is distant also do not discharge time, there is not export license, detecting the spark discharge rate of gained is zero, shown in Fig. 2 zero load, therefore can not carry out loss balancing in electrode movement process;
When electrode and workpiece have just started to contact, now discharging is not continuous print, the spark discharge rate detecting gained is lower, discharge rate is positioned at the low spark discharge rate district shown in Fig. 2, now corresponding electrode wear rate is also lower, and therefore compensation for electrode wear amount can be adjusted in lower level by digital control system in real time;
When electrode contacts completely with workpiece, now electric discharge starts continuous gradually, its discharge voltage waveform can be as shown in Figure 3, overwhelming majority pulse is all being discharged, spark discharge rate remains on high spark discharge rate region shown in Fig. 2, and therefore compensation for electrode wear amount can adjust in higher level according to result of calculation by digital control system in real time;
Contingency, due to the short circuit of reason can the cause interpolar such as interpolar topping up is insufficient, now electrode can stop at once performing procedure and lift certain height perpendicular to electrode direction of feed to the direction of workpiece dorsad, thus stop short-circuit conditions fast, and then the point of interruption is returned in motion at a slow speed, proceed processing, the compensation for electrode wear amount in short circuit moment is with reference to electrode wear rate during the highest discharge spark rate.
Therefore, based on the export license real-time compensation method of spark discharge rate, also the compensation for electrode wear based on real-time discharge scenario is just achieved, electrode wear rate adjusts in real time according to spark discharge rate, and then regulate compensation for electrode wear amount in real time by digital control system, substantially increase the precision of electric spark milling compensation for electrode wear like this.
Detailed description of the invention two: present embodiment is described see Fig. 1, the difference of present embodiment and a kind of export license real-time compensation method based on spark discharge rate described in detailed description of the invention one is, according to voltage across poles value, described judges that the condition whether interpolar occurs to discharge is: voltage across poles value is between zero load and short circuit reference voltage level.
Present embodiment, carry out the real-time adjustment of electrode wear rate in electrical discharge milling machining according to spark discharge rate, compensation for electrode wear amount changes along with the change of spark discharge rate.
Detailed description of the invention three: the difference of present embodiment and a kind of export license real-time compensation method based on spark discharge rate described in detailed description of the invention one is, according to the Time Calculation discharge time after discharge breakdown in processing, and with the time after discharge breakdown in processing for benchmark spark discharge rate w (t
e).
Detailed description of the invention four: the difference of present embodiment and a kind of export license real-time compensation method based on spark discharge rate described in detailed description of the invention one is, by the method determination discharge rate of data analysis and the relation formula of electrode wear rate.
Claims (4)
1., based on an export license real-time compensation method for spark discharge rate, it is characterized in that, the method comprises the steps:
Step one: Real-time Collection voltage across poles value, and judge whether interpolar discharges according to voltage across poles value, when electric discharge occurs interpolar, statistics is carried out to the discharge rate in electric spark milling discharge process and obtains:
T
efor the discharge time in the single pulse time; T is the sampling time; W (t
e) be discharge rate;
Step 2: the relation formula according to discharge rate and electrode wear rate calculates real-time electrode wear rate η (t
e), described according to the relation formula of discharge rate and electrode wear rate is:
η(t
e)＝f(t
e)*w(t
e)，
F (t
e) be the relationship between discharge rate and electrode wear rate; η (t
e) be electrode wear rate,
Step 3: electrode movement control system calculates the electrode obtained proportion of goods damageds η (t according to step 2
e) regulate compensation for electrode wear amount, thus reach the object that compensation for electrode wear carries out according to interpolar discharge rate adjusting in real time.
2. a kind of export license real-time compensation method based on spark discharge rate according to claim 1, it is characterized in that, according to voltage across poles value, described judges that the condition whether interpolar occurs to discharge is: voltage across poles value is between zero load and short circuit reference voltage level.
3. a kind of export license real-time compensation method based on spark discharge rate according to claim 1, it is characterized in that, according to the Time Calculation discharge time after discharge breakdown in processing, and with the time after discharge breakdown in processing for benchmark spark discharge rate w (t
e).
4. a kind of export license real-time compensation method based on spark discharge rate according to claim 1, is characterized in that, by the method determination discharge rate of data analysis and the relation formula of electrode wear rate.
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|---|---|---|---|
| CN201410777505.9A CN104646774B (en) | 2014-12-15 | 2014-12-15 | A kind of export license real-time compensation method based on spark discharge rate |
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|---|---|---|---|
| CN201410777505.9A CN104646774B (en) | 2014-12-15 | 2014-12-15 | A kind of export license real-time compensation method based on spark discharge rate |
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| CN104646774A true CN104646774A (en) | 2015-05-27 |
| CN104646774B CN104646774B (en) | 2016-11-16 |
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Cited By (8)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN105127529A (en) * | 2015-09-06 | 2015-12-09 | 清华大学 | Rotating feeding spindle head mechanism applicable to wire discharge grinding for micro electric spark machining |
| CN105397216A (en) * | 2015-12-08 | 2016-03-16 | 四川成发航空科技股份有限公司 | Combined processing-type electrode used for machining sealing grooves of aero-engine guide blades |
| CN105397218A (en) * | 2015-12-08 | 2016-03-16 | 四川成发航空科技股份有限公司 | Electric spark processing method for sealing grooves of aero engine guide vane |
| CN106077853A (en) * | 2016-07-14 | 2016-11-09 | 大连大学 | A kind of micro-3 d part electric spark milling process method |
| CN106238837A (en) * | 2016-09-05 | 2016-12-21 | 常州大学 | The spark discharge processing method of free electrode and equipment thereof |
| CN109202192A (en) * | 2018-10-31 | 2019-01-15 | 清华大学 | Fine electric spark servo scanning machined parameters preferred method and system |
| CN110508886A (en) * | 2019-08-26 | 2019-11-29 | 哈尔滨工业大学 | A kind of efficient discharging milling processing method and compensation for electrode wear method discharged using pipe electrode shoulder |
| CN114571019A (en) * | 2022-03-16 | 2022-06-03 | 上海空间推进研究所 | Electric spark milling method |
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Cited By (12)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN105127529A (en) * | 2015-09-06 | 2015-12-09 | 清华大学 | Rotating feeding spindle head mechanism applicable to wire discharge grinding for micro electric spark machining |
| CN105397216A (en) * | 2015-12-08 | 2016-03-16 | 四川成发航空科技股份有限公司 | Combined processing-type electrode used for machining sealing grooves of aero-engine guide blades |
| CN105397218A (en) * | 2015-12-08 | 2016-03-16 | 四川成发航空科技股份有限公司 | Electric spark processing method for sealing grooves of aero engine guide vane |
| CN106077853A (en) * | 2016-07-14 | 2016-11-09 | 大连大学 | A kind of micro-3 d part electric spark milling process method |
| CN106077853B (en) * | 2016-07-14 | 2017-12-29 | 大连大学 | A kind of micro- 3 d part electric spark milling process method |
| CN106238837A (en) * | 2016-09-05 | 2016-12-21 | 常州大学 | The spark discharge processing method of free electrode and equipment thereof |
| CN106238837B (en) * | 2016-09-05 | 2018-01-05 | 常州大学 | The spark discharge processing method and its equipment of free electrode |
| CN109202192A (en) * | 2018-10-31 | 2019-01-15 | 清华大学 | Fine electric spark servo scanning machined parameters preferred method and system |
| CN109202192B (en) * | 2018-10-31 | 2019-09-17 | 清华大学 | Fine electric spark servo scanning machined parameters preferred method and system |
| CN110508886A (en) * | 2019-08-26 | 2019-11-29 | 哈尔滨工业大学 | A kind of efficient discharging milling processing method and compensation for electrode wear method discharged using pipe electrode shoulder |
| CN114571019A (en) * | 2022-03-16 | 2022-06-03 | 上海空间推进研究所 | Electric spark milling method |
| CN114571019B (en) * | 2022-03-16 | 2023-10-13 | 上海空间推进研究所 | Electric spark milling method |
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