Research On Energy Consumption Prediction And Monitoring Of Machining Condition In CNC WEDM-MS Process

Manufacturing industry has huge energy consumption and serious pollution emissions,which have a great impact on the global resources and environment.Research on machining energy consumption and corresponding energy-saving strategies is a way to achieve sustainable development.Middle speed wire electrical discharge machining(WEDMMS)is a non-traditional machining and widely used in aerospace,automobile,medical,tool and die manufacturing industries.Compared with traditional machining,middle speed wire electrical discharge machine tools have high automation degree and more energy consumption subunits,which result in more complicated machining process,more concentrated energy consumption and lower energy efficiency.While other traditional machining methods have preliminary achieved intelligence,WEDM is ignored,this is due to difficult data collection and lack of specific processing management software in processing.Therefore,to address the problem in energy consumption acquisition and status monitoring in machining process,monitoring structure and system development are established.Specific steps are as follows:Firstly,energy consumption subunits in WEDM are classified.Secondly,energy models are established according to the energy characteristics of different energy consumption subunits.Thirdly,an energy consumption calculation model combined with specific workpiece information and electrical parameters in machining process is built on the basis of energy models.Furthermore,key parameters in models are defined and the minimizing energy electrical parameters control strategy is recommended.After that,the conditions monitoring system in WEDM processing was studied and development.Monitoring conditions in different mission on the basis of energy consumption characteristics and processing mission.In order to achieve function modules of this monitoring system(i.e.remote management of machining mission information?mission status monitoring?electrical parameters presetting ? processing time predicting ? energy consumption in machining predicting?machine status predicting and other data downloading.),the hard platform of the system is established and the software platform of the system based on Java language is developed.The system built is successfully used in middle speed wire electrical discharge machining.To validate the accuracy of the energy consumption models in processing,two machining process is compared using the information acquired by the system.The results imply that the model is plausible and adequate.Moreover,the proposed saving-energy control strategy is validated,and the experimental investigation and analysis of the test results show that on the basis of guaranteeing surface quality,it can save processing time effectively,reduce energy consumption and significantly improve energy efficiency in pulse system.