Research And Simulated On Micro Low-Speed Wire Electric Discharge Machining Of Rotary Parts

The Micro-wedm,as a kind of high precision,high efficiency machining method,has gradually become one of the effective methods solving precision machining problem of difficult machining materials and micro-scale structure,due to its characteristics of non-contact processing,processing without macro force,without the limitation of hardness and strength.This paper build the rotating mechanism system on the five-axis low-speed wire edm machine,so as to realize the wire cutting of the six axes about the surface not completely through the surface or local with micro rotary structure components.This topic conduct the basic experimental research for the wedm of micro structure of rotary,in order to provide the reference for forming a high precision,high efficiency,high performance and low cost of the structure of rotary processing mean.Based on ANSYS software,this paper conduct the finite element simulation analysis of a hot temperature field for low-speed wedm rotary,and get the rule of temperature change on the craters diameter and radius direction and the rule of craters'sizes change about discharge voltage,discharge current and pulse width.Through the regression fitting analysis,getting the experience formulas of craters' diameter and depth.Based on MATLAB software,setting up the surface topography mathematical model of the single pulse discharge craters,and then concluding the surface topography mathematical model of the continuous pulse discharge random craters.Further more,conducting the modeling and simulation analysis about wedm plane and rotary parts under the multistep to get the workpiece surface topography and surface roughness,which provided the simulation prediction for the actual machining.Box-Behnken experiment was designed by Design-Expert software,and using the response surface method analyzed the law of influence that different non-electrical parameters on the surface roughness and the material removal rate of workpiece,then getting the optimized processing parameter of the machining efficiency and precision.Based on the optimal process parameters combination of the simulation and experiments,conducting the actual processing process study of rotary in wedm.Through designing the wire electrode path,feeding and offset under rough cutting,cutting and refinement,completing the processing of taper electrode,whose top diameter was 796.5?m and bottom diameter was 104.2?m,and ladder shaft,whose big end shaft's diameter was 198.2?m intermediate shaft was 147.5?m and small end shaft diameter was 122.1?gm,which ensured the size error within 5?m.And based on the ladder shaft,completing the processing of "D" glyph micro milling cutter whose blade angle was 20.4°,which provided the processing experience for micro-wedm micro rotary structure.