汽车机械（毕业设计） 英语翻译.doc

High-quality automotive die processing programChamierEDM should be the first choice in the fine processing of die of motor vehicle。 Due to his deep understanding and the painstaking research to EDM machine for half a century， Chamier (Switzerland) as the top processing equipment supplier in the world can provide high-quality solutions for the high value-added automotive tooling 。 Better solution The high demand of upmarket die in the current is that the die have clear surface texture， roughness surface， uniform roughness，clear corner， and its size can be met strictly。 To achieve this requirement， we need to study the mechanism of EDM thoroughly ， to ensure that the size of the processing die refined，clear contour， requesting discharge gap of the processing equipment must be small， which need a radical solution to slove the difficulties of removing debris under the small gap， high quality of Servo System and requirements of stability in processing。 The difficulty of processing and processing area is very different in different directions when we processing in complex cavity， In order to guarantee high efficiency of the discharge gap consistency，we should keep the processing time in the unit area should be equal。Translation technology will be required to distribute time reasonable to digest this uneven phenomenon。 1. problem of Waste discharges in small gapIn order to slove the problem of concentrated discharge under small space， Chamier digital loop servo system to control the stability of processing under small space reliable， due to sophisticated mechanical design and manufacturing technology the machine will be response within 2ms， in the follow 24ms ，10mm of displacement will be happen， This is precisely finishing from the initial discharge of stability required opened the gap。 Since EDM concentrated discharge of corrosion of metals in the first discharge， flanging discharge flange of the pits and a large quantity of corrosion products on the space will be contaminated， leading to the second discharge is near。 This will have in this series of partial discharge pulse until here has become very sag。 In finishing due to a smaller gap discharge， corrosion product proliferation slow， localized pollution will be more serious， which evolved into the follow-up pulse arc， the Ministry of depression more rough。 Therefore， the machine Chamier also used PILOT EXPERT III expert system， The site for the installation of high-grade correctly and quickly detect a pulse each of them classified， Statistics and judgment and cut energy use and change the pulse of pulse parameters， improved the situation of concentrate discharge of pollution effectively， meanwhile servo system will accept a clear trace signal rebound 。The superimposed effect of servo systems of figures for the whole closed-loop and expert system of PILOT EXPERT III can control the length of series pulse under concentrated discharge。 The flatness of the processing of surface will get better when series pulse disappear sooner， but it also brings a problem of low efficiency。 Normally， the highest efficiency occurred when series pulse only to end up in the Arc。 Of course， this could be set by operator according to the requirements plans of workpiece surface map 。 It is necessary to solve the problem of BTA reliably when finishing in a small space。 Normally ，the method is to use the oil-pumping to scour the BTA， it can ensure the processing under stable condition。It will take a great impact to flatness of the workpiece which have been finished and strong erosion will lead to anormal loss in edge and corner ，when the uneven flow cause the uneven chip backlog 。In this regard， the solution Chamier proposed is that do effort to lifting。 In finishing ，the time carrying knives were about 0.2s and the height of lift about 10 times to the discharge gap ，so the knife will raising in 0。6mm。 It is difficult to achieve high speed in such a short period of time and the trip of cutter is such small。 Meanwhile， due to the small space， and the restoration of the disgraced discharge form will be a moment of considerable fluid pressure 500cm2 generally about the finishing area， we could have the reverse 3000N pressure。 So say enough strength simply mention high speed。 Thickened this Chamier the drive screw and greater use of the bearings， to withstand high reverse edge。 The same time to ensure that the small area of the narrow worse snag obtain higher lifting speed， Machine maximum speed was increased two-fold， close to 3m/min， acceleration up to 0.5g。 For example， when the electrode section size of 2mm 20mm， processing cavity depth of 100mm， processing of graphite electrodes used in only 5.5 hours， using copper electrode processing just 8.5h。 It is very difficult to EDM ，if we widen the scope of times under the characteristics of low-speed with the highly demanding In fact，it is very limited to do effect to compress the void time occupied by lifting under servo system 。 Chamier Another measure taken in PILOT EXPERT III control， carrying knives so that the parameters set up with the processing of different changes， it started processing may not carry knives， or random servo carry knives。 Meanwhile gap detection threshold can have the depth and degree of change in the shallow surface processing， BTA patent on cards could relax， to allow more pulse discharge。 The effect is obvious that these two measures applied to the processing of narrow groove and the efficiency can improve 1-2 times。 2. the processing of complex cavityIt is a strength of Chamier to use the technology of translation to allocation of time reasonablely for the processing of complex cavity。 ORB the translation software Chamier used has following characteristics :The electrode moving along the contour of cavity surface according to the directive which have been request， at the same time dressing intensive and bottom precisly，with this methods it is favor to control the size。 electrode could be servo or carry knives in the direction of cavity surface ， keep it no difference compared the intensive of partial surface of every cavity to the discharge of the main straight down or up conventionally， processing is stable and reliable。Discharge to the surrounding in turns according to the speed of 12r/min ， cutting layer by layer and wouldt stay too long in a piont。It can ensure the BTA patency。 Allowance in the every direction of cavity surface at the real-time is link to the translational speed， It will cause the time of dressing spent on long line more than the short line and uneven of allowance can get compensation。 Die in processing， we will face the problem of processing of trace cavity。 It is may be unfamiliar to Chinese users about trace cavity， but its high value-added。 Characterized by small size， less allowance electrode manufacturing difficulties， they require machining， minimize loss， increase the success rate。 Chamier development of this set of special techniques to detect space， processing parameters and servo agile regulation unified integration， the implementation of precision control。 In many machining of micro-cavity， Chamiers get achievements that the electric machine had reached the consistency of processing time does not exceed 5% and 30% of the electrode be decreased in the number。3， the elimination of surface microcracksNow the accepted high value-added Die is longevity of carbide precision die。 Die in the course of processing， water electrolysis work on the damaging effects of the impact on the quality of die major factor ，Its main characteristics are as follows : Open the binder dissolved surface， or surface micro cracks。 Under normal circumstances， surface cracks will not only produce electricity processing， even the grinding， If improper operation will have。 This was mainly due to local overheating， with work on local erosion caused when sudden cold， causing surface cracking。 In fact， the use of the average exchange zero voltage pulsed power and high resistivity deionized water as a working fluid。 Electrolysis destruction has been reduced to the minimum。 Chamiers contribution to this area 。is solve the problem of micro-cracks on surface and technical measures are those ： Use of the peak value and pulse force the workpiece material dished out to gas。 As much higher than the thermal gasification melting heat， most of the heat can be removed and the Temperature of surface of workpiece will not up。 Detect pulse individually and effective。As PILOT-EXPERT expert system can effectively control the discharge of concentrated energy，In order to prevent broken wires at the same time solve the problem of local overheating。Therefore，Chamier machine can guarantee that after finishing the die surface have no microscopic cracks in 1mm thickness of metamorphic ，we will have the same perfect edge like grinding 。WEDM center 。 The two electrode wire are standby at their best condition and exchange reliable and rapid，It can ensure machine under uninterrupted operation。 In Narrow-angle or processing， in general， to spend 0。25mm electrode wire snag twice 0。1mm again changed the filaments for finishing。 In the absence of core processing occasions， may choose to complete with thick wire-EDM-milling to remove most of cushion This fast and save expensive decoration。 Similarly，we can also use the thin wire electrode to processing。micro- cavity， then with thick wire to processing hole or pin hole。This structure of two-wire system is very simple，compared with the original system of go silk，the distance silk walk does not change， the difference is added a rough electrode wire basement， and in each transmission-equipped two wire wheel，we can choice a wire system by pulling key and using the brakes。 Two friendliness guide wire leading to a V-shaped diamond guidance ，if one direction of diamond guidance be worn， can be reused with turning an angle 。 TW machine system does not limit the scope of the application， as long as the machine replaced corresponding annex， It can use 0.03mm electrode wires to finish microfabrication the same，Also it can complete precision cutting the large taper in 30 under the control of the Taper expert system 。Chamier (Switzerland) pursuit the perfect performance of product and high quality of service as their goal。 As the designated partners by F1 ，It provide the machine of EDM used in parts machining。 Chamiers (Switzerland) image often associated with F1 together！高品质的汽车模具加工方案在汽车模具的精细加工中，电加工机床理应是首选。作为世界电加工设备的顶级供应商，瑞士夏米尔以其对电火花加工机床的半个世纪的深刻理解和精心研究，能为高附加值的汽车模具加工提供高品质的解决方案！ 精益求精的解决方案 当前对高档模具的要求是型面纹理清晰，即表面平整、粗糙度均匀、边角清晰、尺寸配合严格合缝。为达到上述要求，就需要透彻地研究电火花加工的机理：要保证所加工出的模具尺寸精、轮廓清，要求电加工设备的放电间隙一定要小，这就需要彻底解决小间隙下排屑困难、伺服性能要求高以及加工平稳性等问题；在加工复杂型腔时，在不同方向上的加工难度和加工面积相差很大。为了保证高效率下放电间隙的一致性，要求单位面积上的加工时间应该相等。这就需要采用平动技术来合理分配时间，以消化这一不均匀。 1、小间隙放电的排屑问题 为解决在小间隙下集中放电的问题，夏米尔采用数字全闭环伺服系统对小间隙加工的稳定性进行可靠的控制,加上机床本身精良的机械设计和制造工艺,使机床在2ms内响应，随后在24ms内做出10mm的位移，而这正好是精加工中从首次放电到稳定工作所需要拉开的距离。由于电火花加工采取集中放电的方式蚀除金属，在首放电后，放电凹坑的翻边凸缘以及大量电蚀产物对间隙会有污染，导致第二次放电也在附近发生。这样就会在此局部产生一连串脉冲放电现象，直到此处变得相当凹陷。在精加工中由于采用小间隙放电，电蚀产物扩散慢，局部污染会比较严重，以致后续脉冲演变成电弧，使凹陷部更加粗糙。因此，夏米尔在机床中还使用了PILOT EXPERT III 专家系统，这一高档的人工智能装置能正确而迅速地检测每一次脉冲，对它们进行分类、统计和判断，并采用切断能量脉冲及改变脉冲参数的方法，有效地改善了集中放电区的污染状况，同时给伺服系统一个明确的微量回升信号。 数字全闭环伺服系统和PILOT EXPERT III 专家系统的作用叠加完全能有效地控制集中放电脉冲串的长度。脉冲串越早终止，所加工型面的平面度就越好，但同时也带来了效率偏低的问题。通常，脉冲串刚好在要起弧的当口终止，这时效率最高。当然这完全可以由操作者按工件图面的要求来设定。 在小间隙精加工中，还必须可靠地解决排屑问题。通常的做法是采用冲抽油冲刷排屑，以保证加工处于稳定状态，但不均匀的流场会造成不均匀的切屑堆积，对加工后的平面度影响很大，而且强烈的冲刷还会引起边角异常损耗。在这方面，夏米尔提出的解决办法是：在抬刀上下功夫。在精加工中抬刀的时间一般为0.2s左右，抬起高度大约有10倍的放电间隙，即将刀抬起0.40.6mm。 在如此短的时间内刀具行程如此之小，是很难达到高速的。同时由于间隙小，在抬起和恢复放电的瞬间还会形成相当大的液压力，一般在大约500cm2的精加工面积上就会产生3000N的反向压力。所以说出力不够根本就谈不上高速。为此夏米尔加粗了传动丝杠，采用更大的轴承，以承受较高的反向力。同时为了保证在小面积的窄糟粗加工中获得较高的抬刀速度，机床的最高速度被提高了2倍，接近3m/min，加速度达0.5g。例如，当电极截面尺寸为2mm20mm、被加工的型腔深度为100mm时，采用石墨电极加工仅需5.5h，采用紫铜电极加工仅需8.5h。像这样将调速范围拉大几倍，对于对低速特性要求极高的电火花成形加工而言是很不容易的。 事实上，仅仅在伺服系统上动脑筋来压缩抬刀占用的无效时间是很有限的。夏米尔采取的另一个措施是在PILOT EXPERT III 的控制下，使抬刀参数的设置随加工深度不同而变化，即开始加工时可以不抬刀，或随机伺服抬刀。同时间隙检测的门槛也可以随深浅度而变，在加工面较浅、排屑通畅时就卡得松一点，以便让更多的脉冲放电。这两项措施在40mm以内的常见窄槽加工中效果很明显，效率可提高12倍。 2、复杂型腔的加工 对于复杂型腔的加工，采用平动技术来合理分配时间是夏米尔的强项。夏米尔采用的ORB平动软件具有如下特点： 指令电极沿着要求的型面轮廓走，同时精修周边和底面，这对控制尺寸极为有利。 电极可在型面方向伺服和抬刀，使得对型腔每个局部的精修与常