Simulation And Experimental Study On The Process Of Block Electrode EDM Copying Microelectrode

With the rapid development of products to miniaturization and precision,micro-EDM machining technology has been widely used in the machining of micro-holes,micro-axes and micro-three-dimensional structures,and has played an important role in the machining of micro-structures and difficult-to-process materials.The forming precision of tool electrode directly affects the machining precision of EDM,so the machining accuracy of tool electrode has always been one of the research hotspots in the field of EDM.At present,block electrode EDM copying is a common tool electrode preparation method,but the micro electrode generally has a certain taper,so it is necessary to carry out theoretical analysis and experimental research on the process of block electrode EDM copying.Firstly,the simulation model of signle pulse discharge temperature field during block electrode EDM copying process was established,the distribution of temperature field and the topography of discharge pits were simulated,and the influence rule of processing parameters on the temperature field during EDM signle pulse discharge process was analyzed,and the signle pulse discharge experiment of the micro-electrode during block electrode EDM copying process was carried out.Secondly,according to the random distribution of discharge points in the process of block electrode EDM copying,the temperature field simulation model of the continuous pulse discharge process of block electrode EDM copying was established,and the formation process of pits on the surface of the micro-electrode and the corrosion process of the micro-electrode were simulated.The effects of peak current and pulse width on the surface morphology of the micro-electrode were analyzed,and the experimental research of block electrode EDM copying was carried out.Finally,the simulation model of electrostatic field,magnetic field and thermal structure in the process of block electrode EDM copying was established,and the electrostatic force,magnetic force and thermal stress in the process of copying were simulated and analyzed.The influence law of processing parameters on the force and deformation in the process of machining the micro-electrode was analyzed,and the mechanism of the deflection deformation of the micro-electrode in the process of EDM copying was revealed.The influence of machining parameters on the taper of the micro-electrode was analyzed and the correctness of the simulation model was verified.