Engineering Application Research On Precision Electrical Discharge Machining Abnormity Channels Of Integral Component

The integral components which contain abnormity channels are widely used in advanced aerospace engine,weapon equipment engine,ship and automobile because of its lightweight,high life,high reliability.However,the geometry of the abnormity channels are complex and the materials are difficult to cut,making its overall manufacturing more difficult.NC-EDM technology has the advantages of high precision and flexibility,which is not restricted by material mechanical properties,and is especially suitable for machining of abnormity channels of integral component.In order to high quality and efficient exert the superiority of EDM abnormity channels of integral component,the engineering application research on precision EDM abnormity channels of integral component was carried out with the typical integral component abnormity channels,and the main research contents include the following several aspects:1.Through the analysis of the main characteristics and difficulties in machining abnormity channels,and the characteristics of the EDM process,formulated the process scheme of abnormity channels.2.Aiming at the difficulty of large stiffness electrode design and trajectory optimization design in the process scheme,an electrode design method was proposed to ensure the integrity of the electrode forming surface and the electrode rigidity;And two different objective functions were used to optimize the motion trajectory,and determined the application of each trajectory in rough and finish machining to improve the machining efficiency and precision.3.After the end of electrical discharge machining simulation,the electrode and the movement trajectory were analyzed to meet the machining precision requirements;And the error analysis module was developed by data point comparison method combined with UG secondary development platform to realize efficient and high precision error analysis of electrodes and abnormity channels of integral component.A typical abnormity channel was used as an example to carry out electrical discharge machining.The finished channel achieved high accuracy and met the requirements of design precision,thus proved the feasibility of the whole process scheme.Through the processing of abnormity channel,the main factors that influenced machining precision in abnormity channel manufacturing were summed up,and the solutions were put forward to improve the precision,which is of great significance to solve the manufacturing problem of the abnormity channels of integral component.