| In our country, there are many high-precision, high melting point, high hardness, high toughness, high strength and high brittleness parts need to process by multi-axes sinking electronic discharge machining(SEDM) tools in the manufacturing fields of aerospace engineering, precision mould die, generating equipment and automotive engineering etc.. However, it has not got a great progress in the research of spark technology in our country, so that it constrains progress in manufacturing industry like aerospace engineering, precision mould die and automotive engineering.At this stage, most of multi-axes SEDM tools are three of four axes linkage SEDM tools in the domestic market, which have many limitations such as unstable processing quality, lower processing efficiency, narrow range of work and lower intelligence. Generally, the main factors restricting the development of SEDM tools are the NC systems, technology database and machine rigidity. When a tool is strengthened the machine rigidity, it can realize the high speed of electrode movement, and so it ameliorates the process quality and broadens the range of work, meanwhile the increasing number of linkage axes make processing great complex curved surfaces more easier. Because the research of multi-axes high-speed SEDM tools (>four axes) will bring new and rapid development in many manufacturing fields again, so it is very necessary to study its rigidity.The three-axis SEDM, in Suzhou Electromaching Machine Tool Research Institute Co. Ltd., is a precision machine and it is also a low speed and low linkage axes tool. While the design cycle is too long if it is to develop a five-axis SEDM through the conventional design method. So, the subject plans to analyze the rigidity of a five-axis SEDM using CAD/CEA co-simulation design method to improve it and shorten the design cycle. The precision of motion axes determines the accuracy of the machine tool which is mainly influenced by dynamic characteristics of motion axes. To this problem, the subject analyze the transient response of the moving link that makes up of X, Y, Z, and C axis in five-axis SEDM and then optimize the structure of parts and the whole moving member. The main tasks for the subject follows:Firstly, create the 3D models of the parts and the assembly; Study the load condition of the main spindle; Solve the transient dynamic analysis of the model in ANSYS Workbench; Research the transient deformation response and transient stress response.Secondly, optimize the tool carriage and ram which are loaded on the equivalent forces, moments and boundary conditions, because the two parts are low strength shown in the result of dynamic analysis; Optimize the whole moving link to improve the rigidity; Research the sensitivity of response parameters to get a set of optimal parameters.Finally, study the uncertainties of the input parameters which are stochastic and uncertain parameters brought in optimal structure analysis. It gets the every parameters' probability. It is more reliable to use the parameters in real design according to the probability.Through the subject, the total deformation maximum reduces 6.99%, the geometry mass decreases 2.67% and the equivalent stress maximum falls 12.24%, which prospectively get the goal of enhancing the machine rigidity and reducing costs. Through the experiment, the result validates that the simulation result is reliable, so the simulation result accommodates some valuable guides to the engineers. |
PDF Full Text Request