The Simulation Of Conic Electrode Forming And Study Of The Surface Machining In Micro-EDM With Fixed Length Compensation Method

The fixed-length compensation methods have been proved to be very effective in processing 3D micro cavity. In machining process, the phenomenon that with the cylindrical rotating electrode and fixed length compensation method the electrode can form the cone character, the corresponding cavity depth will reach a steady status. However, the mechanism that Electrode forms cone character has been not yet clear, so in view of using fixed-length compensation method with cylindrical electrode rotation can form the cone, this article tries to build the geometric model and simulate the fixed-length compensation milling process with MATLAB, and then carries on the experimental verification, aims to reveal the inner mechanism of electrode forming the cone character. On this basis, the article tries to explore the best machining parameters for the second step cavity machining with experiments.First, article gives a detailed introduction of the method of how to establish the geometric model of workpiece and simulation of EDM fixed-length compensation method based on MATLAB, then error analysis is done using the simulation results. And the results indicate that the simulation model is highly agreed with the theoretical results.To verify the accuracy of the simulation model, some experiments of EDM milling with fixed-length compensation method have been done. In this part, the method and the process of manufacturing the electrode on-line have been introduced. Then after the experiment, using the experiment results, some analysis on the cone angle of the cavity have been done to verify the simulation results. And the conclusion is that under certain layer thickness, the simulation results can highly agree with the experiment results and can accurately guide the further cavity machining.With the proven fixed-length compensation method, the 3D micro cavity milling exploration experiments have been operated. In the experiment, the best layer thickness for the second step machining in the first layer is tried to find out. And these modified results all offer the better machining parameters for the next multiple layer cavity machining.