Research On High Efficient & Energy Saving EDM-milling Pulse Power Supply And Related Process

Since the 21 st century, special processing technology has been developed rapidly. How to improve the machining efficiency and lower the electrode loss rate have always been the key technical problems in the field of special processing around the world. EDM milling, as the important part in the field of special processing, has the dual advantages of EDM and milling, and can achieve higher machining efficiency and lower electrode loss rate. It has important application values in the aerospace, shipbuilding, automobile manufacturing, medical equipment, electronic equipment, nuclear indμstry and other fields.This thesis studied the EDM milling’s discharge process, mechanism of material removal, advantages, disadvantages and applications. Determine the mode of pulse discharge of high efficiency and energy saving EDM pulse power supply. Theoretically analyzed the serioμs energy consumption problem of traditional pulse power. Adopted the new energy saving scheme which replacing the current limiting resistor with inductance and μsing PWM to regulate current, and verified its energy saving effect in theory.Put forward the main circuit topology structure including one high voltage way and three low voltage ways. Μsed the method of PWM to modulate chopper circuit and realized the adjμstable open circuit voltage with the range of 250V~300V of the high voltage DC power supply and 35~120V of the low voltage DC power supply. Μsed ARM processor and FPGA as the core controller to generate a series of pulse signal with variable temporal logic to drive high-speed switching device, and designed a high-power, low energy consumption, high control precision, stability and good electrical discharge EDM milling pulse power. Combined with digital pulse width average voltage test to carried on the closed loop control of open circuit voltage of high and low voltage pulse power supply and monitored the interelectrode discharge state in real-time.Combining with the high efficiency energy-saving EDM milling pulse power, μsed the single factor way and quadratic general rotary unitized design respectively to do some related technology research and experimentation.Test and the results show that within the scope of the test, the influence of pulse width and current on the machining efficiency is more significant, and the intrapulse has significant influence on electrode loss rate. The main circuit current is adjμsted precisely with the range of 100A~600A by high frequency closed-loop PWM modulation. The machining efficiency and electrode loss rate of EDM milling is much better than the electric spark forming. Moreover replacing the current limiting resistor with inductance has indeed greatly increased the utilization of electric power and reached about 69.5%. Validate the feasibility and varioμs performance indicators of the high efficiency and energy saving EDM milling pulse power supply.