Design And Optimization Of Ultrasonic Vibration Assisted Arc Machining Control System Based On IMAC400

With the application of hard and brittle materials becoming more and more widely,the application of arc processing is also more and more extensive.Arc machining has the advantages of large discharge energy,high material removal rate and high energy utilization rate.In the process of arc discharge,the breakdown current is large,the released heat is large,the discharge gap is small,the discharge process is extremely unstable,the surface roughness of the material processed is relatively large,and the processing effect is not good.The discharge state of arc machining can be improved by adding the assistant effect of ultrasonic vibration.Advanced numerical control system has great influence on the stability and efficiency of ultrasonic vibration assisted arc machining.This paper mainly studies the control system of ultrasonic vibration assisted arc machining.In this paper,the mechanism of ultrasonic vibration assisted arc machining is researched.The arc processing is divided into three stages:the formation of discharge channel,the throwing of electrode material and the de-ionization of interelectrode medium,so as to explore the mechanism of arc processing conveniently.From the influence of ultrasonic vibration on discharge state and material removal rate in arc machining,the auxiliary effect of ultrasonic vibration on arc machining is researched.A ultrasonic vibration assisted arc machining platform based on IMAC400 is built and tested.The overall structure of the ultrasonic vibration assisted arc machining platform is determined.The parts of the processing platform are designed and analyzed,and the distribution,connection mode and size of the parts of the processing platform are determined.The system control mode of the ultrasonic vibration assisted arc machining platform is determined,the control circuit is designed,and the input and output signals and their circuit connections are determined.The RBF-PID controller is designed in order to optimize the motion control algorithm,which improves the accuracy and stability of the control system of the processing platform.The simulation results show that the RBF-PID controller meets the requirements of arc machining for high precision and anti-interference of motion control system.Under the integrated development environment of vs2010,the motion control card is redeveloped with C++ as the development language.A friendly man-machine interface was designed,and the condition monitoring module,motion control module,program management module and online instruction module were developed.The monitoring and control of the processing platform were accomplished through the cooperation of the modules.T-S fuzzy controller is designed to control the gap of arc machining in real time.The peak gap current and gap voltage are taken as input parameters.Through learning and training,the mathematical model of gap and gap parameters is established to control the gap of arc machining in real time.Through experimental comparison,the effect of ultrasonic vibration assisted on arc discharge is analyzed.The results show that ultrasonic vibration can increase discharge gap,disperse discharge points to make discharge process stable and improve processing quality.The experiments of ultrasonic vibration assisted arc machining with T-S fuzzy controller and traditional servo control are compared.Experiments show that T-S fuzzy controller can make tool electrodes more flexible to feed and retreat in the process of arc machining,greatly reduce the bad phenomena such as the concentration of discharge points and short circuit,and improve the effect of arc machining.