Research On The Process Of High-speed Short Electric Arc Machining(SEAM)

Electrical discharge machining (EDM) is a new machining process using electric energy and thermal energy. The electrode does not contact with the workpiece, and the material removal is caused by the high temperature electric discharge. EDM has unique advantages in cutting materials of high hardness, brittleness and ductility. But the application areas are limited because of the low material removal rate (MRR) of EDM. How to increase the MRR of EDM is always a problem that needs to be addressed urgently.The MRR of high-speed milling of short electrical arc machining (SEAM) proposed in this thesis is high, which can cover the shortage of EDM.In this thesis, the effect laws of technological parameters on the machining effects are studied in this thesis. A process model of SEAM is built using Artificial Neural Network (ANN) of MATLAB. The software of BP-ANN simulating and forecasting system for SEAM processes is designed and developed. The research results are as follows:Retrofitting of machine tool, independent research and development of hybrid power supply, improvement of CNC system, design and development of short circuit detection and automatic tool lifting control system of this project has built the machine tool of high-speed milling of SEAM successfully and realized the high-speed milling of SEAM. And the MRR has reached 5500mm3/min,5.5 to 550 times of EDM.The effect laws of the spindle speed, peak current, flushing pressure and impulse voltage on the MRR, tool wear ratio (TWR) and surface roughness are researched through experiments. Results show that:The MRR and TWR increase as the spindle speed becomes higher, and the surface quality is better. The MRR and TWR also increase with the peak current, but the surface quality becomes worse. The current interruption of the flushing pressure is obvious, so the MRR, EWR and surface roughness decrease when the flushing pressure increase. MRR increases slightly with the impulse voltage, but EWR decreases; surface quality does not change obviously.ANN of MATLAB is used to build the process model of SEAM, and to simulate, forecast the processing results. Confirmatory experiments are carried out to prove the reliability of the model and the veracity of the forecasting results. Experiment results show that the results of ANN simulation and forecast can reflect the process rules of SEAM and it has minor forecast errors.Software of BP-ANN simulating and forecasting system for SEAM processes is designed and developed using GUI of MATLAB, and callback functions of controls are programmed. The software has complete functions and friendly interface. The operational process is simple and the system runs stably.