A Study On The Experiment And Simulation Of EDM Based On Copper Frame Electrode

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.