Wire Structure Optimization And Process Experiment Of Multi-groove Synchronous EDM Cutting Machine

Aiming at the problem of “jumping” of the wire electrode from the wire guide wheel due to the long wire travel length of the multi-tank machine,the large number of wire guide wheels and the complicated wire routing,the machine wire-feeding mechanism is optimized.The problem of unstable power supply during multi-station synchronous machining optimizes the synchronous feed mode of the machine.The tension fluctuation of the electrode wire greatly affects the processing effect,and the bilateral spring and the weight constant tension device are designed.Study the processing characteristics of symmetric synchronous machining and asymmetric synchronous machining.The details are as follows:First,two sets of elastic wire devices were used and arranged symmetrically on a circular machine tool.The invention solves the problems of slack and sagging,large amplitude of vibration and separation of the guide wheel of the wire during th e reciprocating high-speed wire feeding of the wire.At the same time,a new method of winding the wire is designed to increase the efficiency of the wire by about 40%.Secondly,optimize the multi-groove machine tool input mode and conductive device,analyze the synchronous processing and discharge state of different stations,compare the difference of machining discharge between multi-slot machine tool and traditional EDM machine,and solve the problem of unstable and asynchronous power supply.Ensure uniformity of processing and discharge of large workpieces.Optimize the working fluid supply system to achieve simultaneous supply of four stations.Thirdly,the design of bilateral spring and heavy hammer constant tension device solves the problems of large tension range,low sensitivity and large fluctuation of tension in multi-slot machine tools.The tensioning device combined with the double spring and the weight increases the tension wire range to 420 mm.The spring adjustment tension greatly improves the sensitivity and reduces the cushioning during high speed commutation,so that the tension fluctuation range is ±0.2N.Design the man-machine interface of the tension system to monitor the tension change of the wire in real time.Analyze the causes of tension fluctuations,simulate the wire frequency and modal analysis,and propose to reduce the vertical span and reduce the electrode wire jitter scheme.Fourthly,the synchronous double-station and asymmetric three-station synchronous processing tests were designed.The single-factor test was carried out to study the effect of multi-slot machine tool on the groove width and groove depth of Cr12 die steel.The 0.18 mm wire was used to process the Cr12 die steel.A narrow groove of 0.210 mm.The orthogonal test is designed to analyze the influence of parameters such as power supply,pulse width,interpulse multiple,wire frequency and feed rate,and the optimal parameters of machining effect are obtained.Design multi-groove machine multi-station synchronous machining tool setting method to achieve multi-station multi-station tool setting.The orthogonal test of asymmetric three-station synchronous machining is designed to verify the influence of machining process parameters on the synchronous machining of three-station,which provides a theoretical basis for multi-station machining.Comparing the law of synchronous processing of double-station and three-station,the same and difference of synchronous processing of double-station and three-station of multi-slot machine are analyzed.