Research Of Ultrasonic Magnetic Abrasive Finishing Control System Based On PC

With the abroad application of high precision and complex bend surface moulds,the finish machining which is the finally working procedure of moulds machining becomes more and more important. The handwork, which is the traditional means of the polishing of moulds polishing, can't adapt to the need of the moulds industrial development. Then, the Magnetic Abrasive Finishing (MAF) is researched by internal researchers and external ones, and it has been used in the process of the polishing to the free-surface of moulds. MAF not only reduces the intensity of handwork polishing, but also improves the work efficiency of the machining. It also has well flexibility and self-sharp capabilities. But until now, MAF has not been widely used in the manufacturing of moulds because of the difficulties of the magnetic grinds preparation, the low life of the magnetic grinds and the control of the finishing with the universal numerical control equipments, besides the thorough research to the theory.The Ultrasonic Magnetic Abrasive Finishing (UMAF) has been researched as a new-style finish machining presently. It will be used in the finishing of moulds gradually.The compound of the ultrasonic, which is the difference between UMAF and MAF, prolongs the life of the magnetic grinds and improves the milling efficiency availably. But because of the complexity of the technics parameters and the difficulty of online control, UMAF also has the control problem during the machining, which is the one to MAF. The numerical control machine and the MAF control system in existence can't accomplish the machining, because the can do nothing to control the parameters.The MAF is mostly accomplished by the three dimensional coordinate measuring instrument traditionally. The three dimensional coordinate measuring instrument is used to pick-up the surface figure of the mould which is used to complete the machining. Other researchers develop the numerical control system by themselves. But all those means mentioned above have the common problems as follows:1 . High cost Not only the three dimensional coordinate measuring instrument, but also the numerical control system has the high cost. They can hardly be used for the practice widely, which is only for the use of experiments in the period of mechanism study.2 . Low stability Three dimensional coordinate measuring instrument can only pick-up the surface figure, but the magnetic pole circumrotating and the contrail scanning must in virtue of the external equipments, such as step motor, which affects the dependability of the system. The development of the numerical control system is still a huge systems engineering, and the dependability of the system can't be guaranteed.3 . Low grade of the automatization The complicated parameters of the UMAF can but be found through large numbers of optimize-experiments based on the theory research. But the control system in existence that can only accomplish the track scanning can't implement the management and auto-control of the technics parameters.4 . Low using rate The working procedure before polishing of mould is generally the finish machining by the numerical control equipments, which is ignored during the development of the current MAF control system. How to make full use of the numerical control codes of the finish machining is the matter that must be considered to develop the UMAF control system. Based on the reading of large numbers of references, the author analyzed the software and hardware demands of the control system required by the UMAF theory. After taking in the new fruits of the numerical control technology, software technology and the electron technology, the author developed an UMAF control system based on PC.The control system used the industry control computer for the running flat of the control software. The numerical control machine was used to scan the rubbing track. The management and the control of the parameters were realized through the software and data-base technology. This paper includes the follow contents:Firstly, the paper introduced the principle of the UMAF and the factors that influence the results of machining. It analyzed the scarcity of the traditional MAF control system, and demonstrated the scarcity and the feasibility of using numerical control machine to implement the UMAF machining. At the same time, the paper demonstrated the advantage of the PC based system and the feasibility of using it to implement the UMAF. Secondly, based analyzing the software and hardware need of the control system that required by the UMAF theory, the paper discussed the construction of the software system and the hardware system, and expounded the optimize-design of the technics parameters.Thirdly, the paper introduced the design of the modules of the software detailedly while recommending the technology of multithreading and data-base.Fourthly,the paper gave the stability evaluations of the software and the hardware, and putted forward some steps which can advanced the stability of the systemsLastly, a surface rubbing of the finish milling Chilled 45 Steel was given for example to introduce the experiment scheme of the control system. The correctness and the feasibility of the control system were validated after analyzing the results of the experiment.The UMAF Control System based on PC researched in this paper is designed in the configuration and modularization ideas. It has the excellence of low cost, simple operation and the facility of realization. The ordinary NC-Machine of the corporation can be used to realize the UMAF machining with a few hardware equipments appended. It makes sense to the popularization of UMAF currently, and gives references to the intelligent alteration to the national low-grade NC-Machine.