Research On Rotational Electrode And Inner Jetted Dielectric Edm Milling Electrode Wear Compensation Method

EDM milling is a new EDM method, but it is different with the traditional EDM methods. It directly uses a tubular electrode or rod electrode processing, eliminating the complex process of forming the electrode, reducing the time and cost, improving processing efficiency, greatly enhancing the flexibility of production. However, the cross-sectional area of tubular electrodes used in processing is much smaller than the cross-sectional area of cavity to be processed. During the processing, the electrode wear on the length is very enormous,and it has direct impact on the accuracy of processing, which is greatly restricted the practical application of electrical discharge milling. This paper reseasches on the EDM electrode wear compensation methods for rotational electrode and inner jetted dielectric EDM milling.The paper introduces the current status of the electrode wear compensation methods at home and abroad. Analyzes the principle and the advantages and disadvantages of the current electrode wear compensation methods. On the basis of the same loss of electrode theory,by experiment and simulation methods, proposes a prediction and compensation method of electrode wear based on the radial basis function (RBF) neural network.Uses the simulation software FLUENT to simulate the flow field in the discharge gap. Researches on the pressure distribution, the velocity distribution and the removal in debris concentration distribution in the discharge gap fluid flow field, discusses different factors'impacts on the fluid flow field as well as on the EDM milling process and the electrode wear. And the different factors'influences between electrode wear are studied and validated by experiments.Analyzed the simulation and experimental results, establishes a radial basis function (RBF) neural network prediction model. The electrode wear can be calculated timely with the discharge status information which is collected from the machine, and then real-time electrode wear compensation is done by CNC machine. Analyzes the advantages and disadvantages of various electrode wear compensation methods, based on the fixed length compensation method, proposes a compensation method using fixed-length prediction and continuous compensation method. The experiments show that the method can effectively compensate the electrode wear, and the processing results is satisfactory.