Research On High-efficiency And Energy-saving EDM And Arc Composite Milling Pulse Generator

With the development of society and the continuous advancement of the manufacturing industry,it has been challenging for traditional manufacturing to meet people's requirements,and in this situation,non-traditional processing technology has emerged.Electrical discharge machining(EDM),as an essential branch of it,has unique advantages in processing difficultto-cut materials.How to improve processing efficiency,reduce electrode loss,and improve the surface quality of processed workpieces has always been a key focused issue for scholars in this field.As an essential part of the ED milling platform,the ED milling pulse generator provides energy for ED milling.For the traditional ED milling pulse generator,the output energy is small,and the power utilization rate is significantly low.To deal with this challenging problem,this thesis selects "Research on high-efficiency and energy-saving EDM and arc composite milling pulse generator" as the research topic,and carries out systematic theoretical and experimental research work.This would have significant theoretical and engineering application value for improving the processing efficiency of ED milling and the energy-saving of ED milling pulse generator.In this thesis,a high-efficiency and energy-saving EDM and arc composite milling pulse generator is studied.The generator consists of central control system,input rectification and filtering module,adjustable voltage module and electric discharge pulse module,the numerical control current regulating DC module,the driving module,the feedback module and the isolation module.The generator can output high and low voltage composite pulses with tremendous energy for electric discharge milling,which significantly improves the processing efficiency.This thesis uses DC/DC conversion technology to convert the voltage,instead of using the transformer used in the traditional EDM pulse generator.The DC/DC conversion circuit is studied in depth,and the DC/DC conversion circuit scheme is designed.The selection of the components is carried out through calculation,and the PWM circuit and control strategy for controlling the IGBT in the DC/DC conversion are developed,which reduced the volume of the power generator and improved the power usage effectiveness.The central control system based on ARM is developed,which allows the pulse generator to output pulse energy accurately and increases the portability of the pulse generator.The Qt software is used to develop the graphical user interface(GUI)of the host computer of the EDM machine.Besides,the control strategy of the pulse generator is studied to allow the accurate and controllable pulse energy output.In this thesis,to further improve the power usage effectiveness,the high-low-voltage composite strategy of the pulse generator is studied,and a new high-low voltage composite strategy and its control program are developed.To provide real-time feedback and closed-loop control,the average voltage detection circuit and the current detection circuit are designed to detect the voltage and current between the electrode and the workpiece.The real-time feedback is provided to the host computer and the power supply central controller to improve the accuracy of the output parameters of the pulse generator.Finally,to verify the pulse generator's stability of the output electrical parameter and its efficiency and energy saving,the processing performance experiments and comparative experiments with traditional EDM are carried out on the EDM machine platform after the completion of the pulse generator's design and construction.The results show that the processing efficiency of the EDM and the power usage effectiveness of the power generator are greatly improved.