Research On Control Of Spatial Form Of Wire Tension In HSWEDM

In EDM process,the wire electrode of WEDM is influenced not only by interaction of explosive discharge force,electric field force,magnetic field force,working fluid damping force and other forces,but by beating of guide wheel,wire tube and bearing as well,and thus the stability of wire electrode spatial location is poor,resulting in high-speed reciprocating wire EDM wire cutting precision is not high,in addition,it has a greater impact for multiple cutting(commonly known as "Medium speed wire "),large taper cutting and greater-thickness cutting.In this context,a high-speed reciprocating wire constant tension wire walking control mechanism and a new anti-broken wire intelligent wire guide is designed and manufactured,it has a effective control for wire electrode spatial location,on the basis of this,the experimental study of multi cutting,large taper cutting and large thickness cutting is carried out,the main contents are as follows:(1)Using NX6.0 software to design and manufacture the constant tension wire control mechanism,the effective control of the wire tension is realized,and the control precision is in 1N.(2)NX6.0 software is used to design and produce new anti-broken wire intelligent wire guide,improve the electrode wire location precision and stability,reduce wire electrode wear at the same time,also eliminate burning wire and short-circuit phenomenon,prolong the service life of the electrode wire.(3)Both wire constant tension wire walking control mechanism and the new anti-broken wire intelligent wire guide were used for the experiment.The cutting efficiency and precision are improved by about 10% and 20%,and the surface roughness is reduced by about 20%.(4)The wire-winding mechanism has been redesigned according to the cause analysis and simulation results.The experimental results suggest that the non-even wire tension can be effectively controlled in the redesigned mechanism.And the redesigned wire-winding mechanism can improve cutting stability and efficiency in large thickness cutting processes as well as the consistency of workpiece dimension in multi-cutting processes.(5)Multiple factors that influence workpiece's "drum level" are studied,the mechanical model of wire electrode is established too.The results show that discharge explosion force are the main reason caused the drum level of workpiece.