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1、Wire EDM Technology Abstract: With the continuous improvement of machinery manufacturing and the need for precision processing, advanced machinery manufacturing technology also matter of course. In this paper, EDM wire cutting technology and its application and development trends. Key words: Mechani

2、cal manufacturing technology, EDM wire cutting 0.Preface Manufacturing technology is not only a measure of a country an important indicator of the level of technological development is the focus of international technological competition. Machinery manufacturing technology is the study of product de

3、sign, production, processing, manufacturing, selling and use, maintenance services and even the whole process of recycling the engineering disciplines, is to enhance quality, efficiency, competitiveness as the goal, including material flow, information flow and energy flow complete system works. Wit

4、h the development of society, the requirements for products, great changes have taken place, asked to diverse species, update to speed, quality to high-end, the use to be convenient, the price must be reasonable and appearance to appearance, higher degree of automation, service better, more and more

5、 to meet the requirements necessary to adopt advanced machine manufacturing technology. The characteristics of advanced manufacturing technology: (1) it is the 21st century technology. (2) it is the technology for indust of micro-hole slot, narrow, arbitrary curves, with allowance of small, high pre

6、cision, short production cycle, manufacturing highlight the advantages of low cost, has been widely apprial applications. (3) it is to harness the production process systems engineering. (4) it is a technology for global competition. (5) it is the unity of the three elements of market competition. H

7、owever, EDM wire cutting technology is one of advanced manufacturing technology, mechanical production and wide application, it is mainly used for processing a variety of complex shapes and precision small parts, for example, Die punch, die, punch and die, fixed plate, stripper plate and so on, form

8、ing cutter, model, EDM machining the metal electrode, a varietylied in production, the current account abroad WEDM EDM over 60% of the total. The following highlights WEDM machining technology and application of principles and development trends. 1. Principles of WEDM WEDM (Wire cut Electrical Disch

9、arge Machining, referred to as the WEDM), sometimes also known as cutting. The basic physical principle is the presence of free positive ions and electrons to accumulate, and soon to be ionized to form a conductive channel. In this stage, a current between two plates, lead to numerous collisions bet

10、ween particles occur, forming a plasma, and soon increased to 8000 to 12,000 degrees Celsius, melting moments in the two conductors, some of the material at the same time, the electrode and dielectric fluid vaporized, forming a bubble, the rules and it increased until the pressure is very high. And

11、current interruption, the temperature suddenly drop, causing the bubble implosion, the momentum generated to melt the material thrown into the crater, and then the material is corrosive fluid in the dielectric re-condensed into a small ball, and was discharged dielectric fluid. NC-controlled then th

12、e monitoring and control, servo bodies, so that the phenomenon of uniform discharge to achieve the processing of materials to be processed, making it meet the requirements of size and shape precision products. On this basis, our domestic development of the Fast Wire System (HS). Europe and Japan, de

13、veloped the walking system (LS). The main difference is 1, the electrode wire of tungsten and molybdenum alloy wire used, the foreign use of brass. 2, by specification of the working fluid, demonized water used abroad. 3, take the wire of the speed of 11 meters / second or so, abroad for 3 to 5 m /

14、min. 4, we repeat the electrode wire is to use until the broken wire to the foreign is not reused after the walk. 5, our precision than in other countries. According to the electrode wire running at different speeds, and processing quality of different WEDM is usually divided into three categories:

15、the first is to go wire speed WEDM (WEDM-HS), the electrode wire for high-speed reciprocating motion, generally take the wire speed of 8 10m / s, the electrode wire can be reused, the higher processing speed, rapid walking easily lead to the electrode wire and reverse wire jitter when the pause, the

16、 decline in the quality process is the production and use of the main machine species, but also our unique WEDM model; second is the low-speed WEDM wire walk (WEDM-LS), the electrode wire for low-speed one-way movement, generally take the wire speed is lower than 0.2m / s , no longer in use after di

17、scharge electrode wire, smooth, uniform, small jitter, processing, better quality, but the processing speed of lower production and use is the main foreign models. The third class to go wire-speed WEDM and accurately should be called multi-speed to go wire. Is our original, and its principle is to c

18、ut the work piece repeatedly, beginning with fast speed wire tube, strong high-frequency to cut, as the current Fast thread cut, the last knife wire tube with a slower rate than weak high-frequency current to repair light, thereby enhancing the processing finish; and wire-speed reduction, the guide

19、wheel and bearing less jitter, precision is also increased; In addition, the first knife to cut the fastest speed, then cutting and cutting the amount of light repair is very small, therefore, generally Mito time together cut the knife than the speed wire cut faster. Trajectory based on the control

20、of the electrode wire in different forms, can be divided into three WEDM: one is an imitation of shape control, before cutting the conducting wire, pre-create the same shape as the die and the workpiece, the processing time rough and die while the workpiece clamping in the machine table, the electro

21、de wire in the cutting process closely for the trajectory moves close to the edge mode, thereby cutting out the shape with the mold and precision parts to the same; the other is the optical tracking control, the conducting wire cutting before amplification under a certain percentage of part drawings

22、 depict an optical tracking map, the processing machine will be placed in optical pattern tracing stage, the stage of the optical head tracking to follow the ink line graph is always trajectory, then by means of electrical, mechanical linkage, the control machine table with the workpiece relative to

23、 the movement of the electrode wire to do similar figures to cut out shapes with the same pattern to the workpiece; another one is the digital process control, advanced digital automatic control technology, the drive machine according to the geometric shape of the workpiece before processing paramet

24、ers based on pre-programmed processing of the NC machining program automatically, without making look like board and need not draw Enlargement, two forms of control than the previous higher precision and wide range of applications, more than 95% at home and abroad WEDM have adopted CNC. Direct Digit

25、al Control (DNC) EDM wire cutting system can improve the level of automation, the overall productivity and responsiveness. 2. WEDM Characteristics and Application The so-called EDM wire cutting, is to move forward to the filament (diameter of about 0.5mm or less) to make electrodes, the electrode wi

26、re and the spark discharge between the workpiece and simultaneously driven by the shape of the parts required for processing.2.1.WEDM characteristics: (1) it 0.03 0.35mm metal wire to the electrode tool, do not need to create a specific shape of the electrode. (2) Although the process is mainly flat

27、 shape of the object, but in addition to the decision of the inside of the wire diameter foot minimum diameter R (radius + wire discharge gap) such restrictions, no restrictions, no complicated at the beginning of all can be processed. (3) contouring less than the required processing can be effectiv

28、e in saving precious materials. (4) loss of wire can be ignored (using low-loss high-speed cutting away Siqie pulse power; slow walk for a continuous thread cutting one-way wire, always kept in the processing area Sijia new electrode), high precision (5) relies on a tiny computer-controlled electrod

29、e wire traces and space compensation, while both concave and convex mold processing, the gap can be adjusted. (6) by emulsion liquid or to the working fluid from the water, do not have to worry about fire, day and night, no one can be a continuous process. (7) cutting WEDM can be difficult to machin

30、e or can not be the traditional method for processing high hardness, high strength, high brittleness, high-Ren Xing and other conductive materials and semiconductor materials. (8) at the beginning of any complex parts, as long as the preparation of processing can be processed, and thus very suitable

31、 for small batch production of parts and test products, processing, short processing cycle, application flexibility. (9) with four simultaneous axes, can be processed, the following special-shaped body, the shape distortion of the body surface, such as variable taper and spherical parts. (10) proces

32、s, the tools are not in direct contact with the workpiece, there is no significant cutting force, enabling processing of low-rigidity workpiece. (11) and EDM as compared to the wire electrode instead of forming the electrode, eliminating the molding tool design and manufacturing costs electrode Used

33、 to shorten the production lead time. WEDM the disadvantage of low productivity, and can not be blind hole machining parts and ladder surfaces. 2.2.WEDM applications: (1) The trial of new products: new product development process requires a single piece samples, use of wire cutting parts cut out dir

34、ectly, without molds, which can greatly shorten the development cycle of new products and reduce trial costs. Such as stamping, the die is not expected to open Chula, first with a wire cutting for forming such a model for subsequent processing, be verified before blanking die manufacturing. (2) proc

35、essing of special materials: cutting some of the high hardness, high melting point metal, the use of machine processing methods is almost impossible, and economical use of line cutting can ensure accuracy. (3) processing mold parts: mainly used in EDM wire cutting dies, extrusion dies, plastic dies,

36、 EDM electrodes cavity mold processing, the EDM wire cutting speed and accuracy of the rapid increase has reached can compete with the coordinates of the degree of grinding. For example, the small die, the material is tool steel, in the past with a separate mold and method of curve grinding machinin

37、g, EDM wire cutting now switch to the overall processing methods, manufacturing cycle can be shortened 3 / 4 to 5 / 4, reduce the cost of 2 / 3 / 4, with high precision, the work does not require skilled operators. Therefore, some industrial countries such as precision grinding washed process has be

38、en EDM and WEDM replaced. 2.3.WEDM application areas:WEDM is mainly used for a variety of dies, plastic molds, powder metallurgy molds composed of two-dimensional and three-dimensional ruled surface of the mold and parts. Can cut a variety of templates, magnets, silicon steel, semiconductor material

39、s or precious metals, but also for micro-machining, shaped slot and the standard specimen processing defects. Widely used in electronic equipment, precision machine tools, light industrial, military and so on. (1) plane shape of the metal mold processing: die, powder metallurgy mold, drawing die, ex

40、trusion die machining (2) three-dimensional shape of the metal mold processing: Die by the withdrawal of the die groove machining, plastic with metal dies, plastic mold separation surface processing (3) EDM: production of complex shapes using micro-electrodes the electrode process, the general proce

41、ssing of perforated electrode, the electrode process with taper mold (4) test products and parts processing: prototype parts directly to processing, batch processing of small variety of parts, special materials, spare parts processing, materials, processing of specimens (5) profile gauge processing:

42、 measuring a variety of card board processing, the cam and the template processing, shape forming car (6) micro-processing: Processing of chemical fiber nozzle, shaped slot and narrow channel processing, standard processing defects 3. WEDM technology status Currently, the cutting speed WEDM has been

43、 widespread over the past 20 40mm2/min increased to 100mm2/min above, and some can reach 260mm2/min, machining accuracy is 0.01mm, the surface roughness of the workpiece Ra1.25 2.5m, which can meet the general mold machining and other complex parts manufacturing requirements. With the development of

44、 science and technology, the manufacture of various products have become increasingly demanding of wire cutting technology has also put forward higher requirements. Abroad (Europe, America, Japan, etc.) to go low-speed research and development of CNC wire electric discharge machines to meet the requ

45、irements of the manufacturing process technology, the use of closed-loop digital delivery (straight) flow servo control system to ensure excellent dynamic performance and high positioning accuracy, precision can be controlled in a number of microns or less. At the same time with a digital adaptive c

46、ontrol of power tools, automatic wear silk, automatic removable waste, short-circuit automatic rollback and other automated techniques, in addition to the electrode wire tension and the working fluid pressure can be controlled. Due to the use of new technology and focus on updating the computer soft

47、ware technology and development of low-speed wire cutting away the process indicators have reached a very high level. Even if the machining of complex shape, the maximum cutting speed of more than 300mm2/min; size precision can reach 2 5m; surface roughness can be achieved Ra0.1 0.2m (multiple cutti

48、ng). High degree of automation of machine tools, processing stability, has been the development of unmanned machining. 3.1.WEDM technology trends: WEDM due to loss of electrode wire, and precision mechanical parts of the structure, into the open-loop control to the system, processing of changes in w

49、orking fluid conductivity, temperature processing environment and its own processing characteristics (such as wire speed operation fast, more vibration source, guide wheel wear large) and other factors, machining accuracy is limited. The current status of the machine, to a relatively short time and

50、low-speed wire EDM to go to compete in the processing precision, the difficulty is quite large, and research and development costs will be high, the machine will significantly increase manufacturing costs From the perspective of reality and the market are not considered appropriate. Therefore, the d

51、evelopment strategy WEDM weaknesses, to develop middle and low machine-based, so that the machine to the appropriate precision, good stability and easy processing direction, to meet growing production needs. Currently on the market high-speed wire cutting away the biggest advantage is to have a good

52、 cost performance, the machine must take this as further development of the basic starting point, not too much emphasis on precision machining, and overlook the factors that cost performance machine. In contravention of this principle, machine manufacturers and users are difficult to accept. In the

53、short period of time, so that the processing performance of WEDM have greatly improved. WEDM to further development, we must get rid of SBC as a numerical control system, the use of new NC system. At present, there go the high-speed PC-based CNC wire cutting machine, but its main function is process

54、ing path programming, machine tool control is far from perfect, there is no full use of PC resources. In the use of new technologies, new processes must also attach importance to the law of WEDM process based on thorough and detailed theoretical and experimental research, this is a very important pa

55、rt. 4. Conclusion At present, artificial intelligence technology has started in the WEDM in the research, however, the depth and breadth of research is still not enough. There are many aspects to be studied further: (1) of the Servo WEDM inverter control has to rely on the operator, so the operating

56、 staff strength, machine performance of the play is limited. Artificial intelligence fuzzy control technology is an important aspect of technology, it can imitate the skilled control of machine tools, EDM machine has been successfully applied in EDM wire cutting has a good prospect. (2) concluded ov

57、er the years to go wire cutting high-speed processing results, the establishment of appropriate knowledge base and expert systems, reducing the difficulty of the operation of machine tools is essential. (3) adaptive processing parameters, etc. can make a difference. The latest artificial intelligenc

58、e technology into the development of WEDM, the development of high-speed wire cutting away parts of the intelligent control and enforcement agencies, which is the current national development priorities are consistent with high-tech industry, has important practical significance. 电火花线切割技术摘要：随着机械制造业水

59、平的不断提高和产品加工精度的需要，先进的机械制造技术的应用也就顺理成章。本文主要介绍电火花线切割技术及其应用和发展趋势。关键词：机械制造技术，电火花线切割0 绪言制造技术不仅是衡量一个国家科技发展水平的重要标志,也是国际间科技竞争的重点。机械制造技术是研究产品设计、生产、加工制造、销售使用、维修服务乃至回收再生的整个过程的工程学科,是以提高质量、效益、竞争力为目标,包含物质流、信息流和能量流的完整的系统工程。随着社会的发展,人们对产品的要求也发生了很大变化,要求品种要多样、更新要快捷、质量要高档、使用要方便、价格要合理、外形要美观、自动化程度要高、售后服务要好、要满足人们越来越高的要求,就必须

60、采用先进的机械制造技术。先进制造技术的特点有：（1）它是面向21世纪的技术。（2）是面向工业应用的技术。（3）是驾驭生产过程的系统工程。（4）是面向全球竞争的技术。（5）是市场竞争三要素的统一。然而电火花线切割技术是先进制造技术之一，在机械生产中应用范围广，它主要用于加工各种形状复杂和精密细小的工件，例如冲裁模的凸模、凹模、凸凹模、固定板、卸料板等，成形刀具、样板、电火花成型加工用的金属电极，各种微细孔槽、窄缝、任意曲线等，具有加工余量小、加工精度高、生产周期短、制造成本低等突出优点，已在生产中获得广泛的应用，目前国内外的电火花线切割机床已占电加工机床总数的60以上。 下面着重介绍电火花线切割

61、技术的加工原理及其应用范围和发展趋势。1 电火花线切割加工原理电火花线切割加工（Wire cut Electrical Discharge Machining，简称WEDM），有时又称线切割。其基本物理原理是自由正离子和电子在场中积累，很快形成一个被电离的导电通道。在这个阶段，两板间形成电流。导致粒子间发生无数次碰撞，形成一个等离子区，并很快升高到8000到12000度的高温，在两导体表面瞬间熔化一些材料，同时，由于电极和电介液的汽化，形成一个气泡，并且它的压力规则上升直到非常高。然后电流中断，温度突然降低，引起气泡内向爆炸，产生的动力把溶化的物质抛出弹坑，然后被腐蚀的材料在电介液中重新凝结成

62、小的球体，并被电介液排走。然后通过NC控制的监测和管控，伺服机构执行，使这种放电现象均匀一致，从而达到加工物被加工，使之成为合乎要求之尺寸大小及形状精度的产品。我们国内在此基础上发展了快走丝系统(HS)。欧美和日本发展了慢走系统(LS)。主要区别是1、电极丝我国采用钨钼合金丝，国外采用黄铜丝。2,我国采用皂化工作液，国外采用去离子水。 3、我国的走丝速度为11米/秒左右，国外为35米/分。4、我们的电极丝是重复利用的直到断丝为至,国外是走过后不再重用。5、我们的精度不如国外高。根据电极丝的运行速度不同，及加工质量不同，电火花线切割机床通常分为三类：第一类是高速走丝电火花线切割机床（WEDM-H

63、S），其电极丝作高速往复运动，一般走丝速度为810m/s，电极丝可重复使用，加工速度较高，但快速走丝容易造成电极丝抖动和反向时停顿，使加工质量下降，是我国生产和使用的主要机种，也是我国独创的电火花线切割加工模式；第二类是低速走丝电火花线切割机床（WEDM-LS），其电极丝作低速单向运动，一般走丝速度低于0.2m/s，电极丝放电后不再使用，工作平稳、均匀、抖动小、加工质量较好，但加工速度较低，是国外生产和使用的主要机种。第三类中速走丝电火花线切割机床，准确地应该叫“多速走丝”。是我国独创的，其原理是对工件作多次反复的切割，开头用较快丝筒速度、较强高频来切割，就如现在的快走丝线切割，最后一刀用较慢

64、丝筒速度、较弱高频电流来修光，从而提高了加工光洁度；而且丝速减低后，导轮和轴承的抖动少了，加工精度也提高了；另外，第一刀以最快的速度切割，后来的切割和修光的切割量都非常少，因此，一般三刀切割的时间加起来也比快走丝的一刀切割要快。 根据对电极丝运动轨迹的控制形式不同，电火花线切割机床又可分为三种：一种是模仿形控制，其在进行线切割加工前，预先制造出与工件形状相同的模，加工时把工件毛坯和模同时装夹在机床工作台上，在切割过程中电极丝紧紧地贴着模边缘作轨迹移动，从而切割出与模形状和精度相同的工件来；另一种是光电跟踪控制，其在进行线切割加工前，先根据零件图样按一定放大比例描绘出一张光电跟踪图，加工时将图样

65、置于机床的光电跟踪台上，跟踪台上的光电头始终追随墨线图形的轨迹运动，再借助于电气、机械的联动，控制机床工作台连同工件相对电极丝做相似形的运动，从而切割出与图样形状相同的工件来；再一种是数字程序控制，采用先进的数字化自动控制技术，驱动机床按照加工前根据工件几何形状参数预先编制好的数控加工程序自动完成加工，不需要制作模样板也无需绘制放大图，比前面两种控制形式具有更高的加工精度和广阔的应用范围，目前国内外95以上的电火花线切割机床都已采用数控化。直接数字控制(DNC)电火花线切割系统可以提高系统的自动化水平、总体的生产效率和响应速度 。2 电火花线切割加工的特点与应用 所谓电火花线切割，就是以移动着的细丝（直径约在0.5mm以内）做电极，在电极丝与工件之间产生火花放电，并同时按所要求的形状驱动工件进行加工。电火花线切割加工的特点：（1）它以0.030.35mm的金属线为电极工具，不需要制造特定形状的电极。（2）虽然加工的对象主要是平面形状，但是除了有金属丝直径决定的内侧脚的最小直径R（金属线半径+放电间隙）这样的限制外，任何的限制外，任何复杂的开头都可以加工。（3）轮廓加工所需加工的余量少，能有效地节约贵重的材料。（4）可无视电极丝损耗（高速走丝切割采用低损耗脉冲电源；慢速走丝线切割采用单向连续供丝，在加工区总是保持新电极丝加工），加工精度高（5）依靠微型计算机控制电极丝轨迹和间