Development Of Multi-channel Synchronous WEDM

With the rapid development of automobile industry, the demand of automobile tire mold also increased dramatically. In the tire mold manufacturing,according to the model and specifications,tire mold needs to be cut into multiple copies and ranged.The existing tire mold cutting manufacturing process is to use common line cutting that will lead to uneven distribution of internal stress and deformation,and the machining efficiency is extremely low,cutting time in seven to fifteen days.Therefore,developing the new type cutting equipment of high efficiency and low cost is very urgent.In this paper,in view of the tire mold block cutting processing efficency,on the basis of single slot and double groove wire-cut EDM machine,we design a multi-channel synchronous WEDM for tire mold or large annular parts.When processing,the position of thread rolling tube and the workbench(workpiece) doesn’t change,multiple wire frame move independently,to implement it that a wire may carry on wire cutting processing for multiple locations of a workpiece,not only to increase the production efficiency exponentially,but also to make the distribution of the internal stress of workpiece more uniform and less deformation.At the same time,it can install the workpiece after loading wire that is beneficial to operation and can deflect wire frame angle easily for asymmetric processing,this is a highly efficient and high quality new technology for ring parts block cutting,and is also the WEDM processing technology to further expand.In the structural design,through the special topology and the clever arrangement of idler pulley group,the machine forms the four direction of wire electrode processing section to cut out multiple narrow slots continuously and simultaneously. On the wire walking system,we design the wire electrode constant tension structure to ensure the wire electrode tension state.For different thickness and height of ring workpiece,we design movable fixture and adjustable height and angle of wire frame,to implement synchronous symmetric and asymmetric cutting process of annular parts,also greatly improving the efficiency of the cutting process,and providing a thought for developing the machine for processing more ring parts in the furture.In the project design of control system, in view of the synchronous cutting particularity of multi-channel machine,in order to avoid stepper motor out of step when the pulse power supply in air travel, that can limit the output voltage of sampling circuit so as not to realize stepper motor variable speed feed.Subject put forward to use dsPIC6010A microcontroller as the control system that has some action control functions such as Fast forward,Labo into,Processing the fallback and Short circuit back,which solves the defects that common WEDM-HS can only uniform feed,and greatly improves the cutting efficiency.The characteristics and innovation of subject:overcome the deficiency of the existing cutting tire mold,achieve that a wire can cut more than a narrow slot at the same time,improve the cutting efficiency,make the internal stress distribution of workpiece more uniform and machining deformation smaller,to improve the quality of workpiece.This is a highly efficient and low cost new machine technology solution. Its successful development will have important theoretical and practical significance for improving the level of special processing technology and promoting the development of manufacturing industry of new and high technology in our country,especially for improving the machining efficiency and enhancing the market competitiveness in automobile tire mold industry.