机械制造加工 外文翻译 外文文献 英文文献 电火花线切割技术

WIREEDMTECHNOLOGYABSTRACTWITHTHECONTINUOUSIMPROVEMENTOFMACHINERYMANUFACTURINGANDTHENEEDFORPRECISIONPROCESSING,ADVANCEDMACHINERYMANUFACTURINGTECHNOLOGYALSOMATTEROFCOURSEINTHISPAPER,EDMWIRECUTTINGTECHNOLOGYANDITSAPPLICATIONANDDEVELOPMENTTRENDSKEYWORDSMECHANICALMANUFACTURINGTECHNOLOGY,EDMWIRECUTTING0PREFACEMANUFACTURINGTECHNOLOGYISNOTONLYAMEASUREOFACOUNTRYANIMPORTANTINDICATOROFTHELEVELOFTECHNOLOGICALDEVELOPMENTISTHEFOCUSOFINTERNATIONALTECHNOLOGICALCOMPETITIONMACHINERYMANUFACTURINGTECHNOLOGYISTHESTUDYOFPRODUCTDESIGN,PRODUCTION,PROCESSING,MANUFACTURING,SELLINGANDUSE,MAINTENANCESERVICESANDEVENTHEWHOLEPROCESSOFRECYCLINGTHEENGINEERINGDISCIPLINES,ISTOENHANCEQUALITY,EFFICIENCY,COMPETITIVENESSASTHEGOAL,INCLUDINGMATERIALFLOW,INFORMATIONFLOWANDENERGYFLOWCOMPLETESYSTEMWORKSWITHTHEDEVELOPMENTOFSOCIETY,THEREQUIREMENTSFORPRODUCTS,GREATCHANGESHAVETAKENPLACE,ASKEDTODIVERSESPECIES,UPDATETOSPEED,QUALITYTOHIGHEND,THEUSETOBECONVENIENT,THEPRICEMUSTBEREASONABLEANDAPPEARANCETOAPPEARANCE,HIGHERDEGREEOFAUTOMATION,SERVICEBETTER,MOREANDMORETOMEETTHEREQUIREMENTSNECESSARYTOADOPTADVANCEDMACHINEMANUFACTURINGTECHNOLOGYTHECHARACTERISTICSOFADVANCEDMANUFACTURINGTECHNOLOGY1ITISTHE21STCENTURYTECHNOLOGY2ITISTHETECHNOLOGYFORINDUSTOFMICROHOLESLOT,NARROW,ARBITRARYCURVES,WITHALLOWANCEOFSMALL,HIGHPRECISION,SHORTPRODUCTIONCYCLE,MANUFACTURINGHIGHLIGHTTHEADVANTAGESOFLOWCOST,HASBEENWIDELYAPPRIALAPPLICATIONS3ITISTOHARNESSTHEPRODUCTIONPROCESSSYSTEMSENGINEERING4ITISATECHNOLOGYFORGLOBALCOMPETITION5ITISTHEUNITYOFTHETHREEELEMENTSOFMARKETCOMPETITIONHOWEVER,EDMWIRECUTTINGTECHNOLOGYISONEOFADVANCEDMANUFACTURINGTECHNOLOGY,MECHANICALPRODUCTIONANDWIDEAPPLICATION,ITISMAINLYUSEDFORPROCESSINGAVARIETYOFCOMPLEXSHAPESANDPRECISIONSMALLPARTS,FOREXAMPLE,DIEPUNCH,DIE,PUNCHANDDIE,FIXEDPLATE,STRIPPERPLATEANDSOON,FORMINGCUTTER,MODEL,EDMMACHININGTHEMETALELECTRODE,AVARIETYLIEDINPRODUCTION,THECURRENTACCOUNTABROADWEDMEDMOVER60OFTHETOTALTHEFOLLOWINGHIGHLIGHTSWEDMMACHININGTECHNOLOGYANDAPPLICATIONOFPRINCIPLESANDDEVELOPMENTTRENDS1PRINCIPLESOFWEDMWEDMWIRECUTELECTRICALDISCHARGEMACHINING,REFERREDTOASTHEWEDM,SOMETIMESALSOKNOWNASCUTTINGTHEBASICPHYSICALPRINCIPLEISTHEPRESENCEOFFREEPOSITIVEIONSANDELECTRONSTOACCUMULATE,ANDSOONTOBEIONIZEDTOFORMACONDUCTIVECHANNELINTHISSTAGE,ACURRENTBETWEENTWOPLATES,LEADTONUMEROUSCOLLISIONSBETWEENPARTICLESOCCUR,FORMINGAPLASMA,ANDSOONINCREASEDTO8000TO12,000DEGREESCELSIUS,MELTINGMOMENTSINTHETWOCONDUCTORS,SOMEOFTHEMATERIALATTHESAMETIME,THEELECTRODEANDDIELECTRICFLUIDVAPORIZED,FORMINGABUBBLE,THERULESANDITINCREASEDUNTILTHEPRESSUREISVERYHIGHANDCURRENTINTERRUPTION,THETEMPERATURESUDDENLYDROP,CAUSINGTHEBUBBLEIMPLOSION,THEMOMENTUMGENERATEDTOMELTTHEMATERIALTHROWNINTOTHECRATER,ANDTHENTHEMATERIALISCORROSIVEFLUIDINTHEDIELECTRICRECONDENSEDINTOASMALLBALL,ANDWASDISCHARGEDDIELECTRICFLUIDNCCONTROLLEDTHENTHEMONITORINGANDCONTROL,SERVOBODIES,SOTHATTHEPHENOMENONOFUNIFORMDISCHARGETOACHIEVETHEPROCESSINGOFMATERIALSTOBEPROCESSED,MAKINGITMEETTHEREQUIREMENTSOFSIZEANDSHAPEPRECISIONPRODUCTSONTHISBASIS,OURDOMESTICDEVELOPMENTOFTHEFASTWIRESYSTEMHSEUROPEANDJAPAN,DEVELOPEDTHEWALKINGSYSTEMLSTHEMAINDIFFERENCEIS1,THEELECTRODEWIREOFTUNGSTENANDMOLYBDENUMALLOYWIREUSED,THEFOREIGNUSEOFBRASS2,BYSPECIFICATIONOFTHEWORKINGFLUID,DEMONIZEDWATERUSEDABROAD3,TAKETHEWIREOFTHESPEEDOF11METERS/SECONDORSO,ABROADFOR3TO5M/MIN4,WEREPEATTHEELECTRODEWIREISTOUSEUNTILTHEBROKENWIRETOTHEFOREIGNISNOTREUSEDAFTERTHEWALK5,OURPRECISIONTHANINOTHERCOUNTRIESACCORDINGTOTHEELECTRODEWIRERUNNINGATDIFFERENTSPEEDS,ANDPROCESSINGQUALITYOFDIFFERENTWEDMISUSUALLYDIVIDEDINTOTHREECATEGORIESTHEFIRSTISTOGOWIRESPEEDWEDMWEDMHS,THEELECTRODEWIREFORHIGHSPEEDRECIPROCATINGMOTION,GENERALLYTAKETHEWIRESPEEDOF810M/S,THEELECTRODEWIRECANBEREUSED,THEHIGHERPROCESSINGSPEED,RAPIDWALKINGEASILYLEADTOTHEELECTRODEWIREANDREVERSEWIREJITTERWHENTHEPAUSE,THEDECLINEINTHEQUALITYPROCESSISTHEPRODUCTIONANDUSEOFTHEMAINMACHINESPECIES,BUTALSOOURUNIQUEWEDMMODELSECONDISTHELOWSPEEDWEDMWIREWALKWEDMLS,THEELECTRODEWIREFORLOWSPEEDONEWAYMOVEMENT,GENERALLYTAKETHEWIRESPEEDISLOWERTHAN02M/S,NOLONGERINUSEAFTERDISCHARGEELECTRODEWIRE,SMOOTH,UNIFORM,SMALLJITTER,PROCESSING,BETTERQUALITY,BUTTHEPROCESSINGSPEEDOFLOWERPRODUCTIONANDUSEISTHEMAINFOREIGNMODELSTHETHIRDCLASSTOGOWIRESPEEDWEDMANDACCURATELYSHOULDBECALLED“MULTISPEEDTOGOWIRE“ISOURORIGINAL,ANDITSPRINCIPLEISTOCUTTHEWORKPIECEREPEATEDLY,BEGINNINGWITHFASTSPEEDWIRETUBE,STRONGHIGHFREQUENCYTOCUT,ASTHECURRENTFASTTHREADCUT,THELASTKNIFEWIRETUBEWITHASLOWERRATETHANWEAKHIGHFREQUENCYCURRENTTOREPAIRLIGHT,THEREBYENHANCINGTHEPROCESSINGFINISHANDWIRESPEEDREDUCTION,THEGUIDEWHEELANDBEARINGLESSJITTER,PRECISIONISALSOINCREASEDINADDITION,THEFIRSTKNIFETOCUTTHEFASTESTSPEED,THENCUTTINGANDCUTTINGTHEAMOUNTOFLIGHTREPAIRISVERYSMALL,THEREFORE,GENERALLYMITOTIMETOGETHERCUTTHEKNIFETHANTHESPEEDWIRECUTFASTERTRAJECTORYBASEDONTHECONTROLOFTHEELECTRODEWIREINDIFFERENTFORMS,CANBEDIVIDEDINTOTHREEWEDMONEISANIMITATIONOFSHAPECONTROL,BEFORECUTTINGTHECONDUCTINGWIRE,PRECREATETHESAMESHAPEASTHEDIEANDTHEWORKPIECE,THEPROCESSINGTIMEROUGHANDDIEWHILETHEWORKPIECECLAMPINGINTHEMACHINETABLE,THEELECTRODEWIREINTHECUTTINGPROCESSCLOSELYFORTHETRAJECTORYMOVESCLOSETOTHEEDGEMODE,THEREBYCUTTINGOUTTHESHAPEWITHTHEMOLDANDPRECISIONPARTSTOTHESAMETHEOTHERISTHEOPTICALTRACKINGCONTROL,THECONDUCTINGWIRECUTTINGBEFOREAMPLIFICATIONUNDERACERTAINPERCENTAGEOFPARTDRAWINGSDEPICTANOPTICALTRACKINGMAP,THEPROCESSINGMACHINEWILLBEPLACEDINOPTICALPATTERNTRACINGSTAGE,THESTAGEOFTHEOPTICALHEADTRACKINGTOFOLLOWTHEINKLINEGRAPHISALWAYSTRAJECTORY,THENBYMEANSOFELECTRICAL,MECHANICALLINKAGE,THECONTROLMACHINETABLEWITHTHEWORKPIECERELATIVETOTHEMOVEMENTOFTHEELECTRODEWIRETODOSIMILARFIGURESTOCUTOUTSHAPESWITHTHESAMEPATTERNTOTHEWORKPIECEANOTHERONEISTHEDIGITALPROCESSCONTROL,ADVANCEDDIGITALAUTOMATICCONTROLTECHNOLOGY,THEDRIVEMACHINEACCORDINGTOTHEGEOMETRICSHAPEOFTHEWORKPIECEBEFOREPROCESSINGPARAMETERSBASEDONPREPROGRAMMEDPROCESSINGOFTHENCMACHININGPROGRAMAUTOMATICALLY,WITHOUTMAKINGLOOKLIKEBOARDANDNEEDNOTDRAWENLARGEMENT,TWOFORMSOFCONTROLTHANTHEPREVIOUSHIGHERPRECISIONANDWIDERANGEOFAPPLICATIONS,MORETHAN95ATHOMEANDABROADWEDMHAVEADOPTEDCNCDIRECTDIGITALCONTROLDNCEDMWIRECUTTINGSYSTEMCANIMPROVETHELEVELOFAUTOMATION,THEOVERALLPRODUCTIVITYANDRESPONSIVENESS2WEDMCHARACTERISTICSANDAPPLICATIONTHESOCALLEDEDMWIRECUTTING,ISTOMOVEFORWARDTOTHEFILAMENTDIAMETEROFABOUT05MMORLESSTOMAKEELECTRODES,THEELECTRODEWIREANDTHESPARKDISCHARGEBETWEENTHEWORKPIECEANDSIMULTANEOUSLYDRIVENBYTHESHAPEOFTHEPARTSREQUIREDFORPROCESSING21WEDMCHARACTERISTICS1IT003035MMMETALWIRETOTHEELECTRODETOOL,DONOTNEEDTOCREATEASPECIFICSHAPEOFTHEELECTRODE2ALTHOUGHTHEPROCESSISMAINLYFLATSHAPEOFTHEOBJECT,BUTINADDITIONTOTHEDECISIONOFTHEINSIDEOFTHEWIREDIAMETERFOOTMINIMUMDIAMETERRRADIUSWIREDISCHARGEGAPSUCHRESTRICTIONS,NORESTRICTIONS,NOCOMPLICATEDATTHEBEGINNINGOFALLCANBEPROCESSED3CONTOURINGLESSTHANTHEREQUIREDPROCESSINGCANBEEFFECTIVEINSAVINGPRECIOUSMATERIALS4LOSSOFWIRECANBEIGNOREDUSINGLOWLOSSHIGHSPEEDCUTTINGAWAYSIQIEPULSEPOWERSLOWWALKFORACONTINUOUSTHREADCUTTINGONEWAYWIRE,ALWAYSKEPTINTHEPROCESSINGAREASIJIANEWELECTRODE,HIGHPRECISION5RELIESONATINYCOMPUTERCONTROLLEDELECTRODEWIRETRACESANDSPACECOMPENSATION,WHILEBOTHCONCAVEANDCONVEXMOLDPROCESSING,THEGAPCANBEADJUSTED6BYEMULSIONLIQUIDORTOTHEWORKINGFLUIDFROMTHEWATER,DONOTHAVETOWORRYABOUTFIRE,DAYANDNIGHT,NOONECANBEACONTINUOUSPROCESS7CUTTINGWEDMCANBEDIFFICULTTOMACHINEORCANNOTBETHETRADITIONALMETHODFORPROCESSINGHIGHHARDNESS,HIGHSTRENGTH,HIGHBRITTLENESS,HIGHRENXINGANDOTHERCONDUCTIVEMATERIALSANDSEMICONDUCTORMATERIALS8ATTHEBEGINNINGOFANYCOMPLEXPARTS,ASLONGASTHEPREPARATIONOFPROCESSINGCANBEPROCESSED,ANDTHUSVERYSUITABLEFORSMALLBATCHPRODUCTIONOFPARTSANDTESTPRODUCTS,PROCESSING,SHORTPROCESSINGCYCLE,APPLICATIONFLEXIBILITY9WITHFOURSIMULTANEOUSAXES,CANBEPROCESSED,THEFOLLOWINGSPECIALSHAPEDBODY,THESHAPEDISTORTIONOFTHEBODYSURFACE,SUCHASVARIABLETAPERANDSPHERICALPARTS10PROCESS,THETOOLSARENOTINDIRECTCONTACTWITHTHEWORKPIECE,THEREISNOSIGNIFICANTCUTTINGFORCE,ENABLINGPROCESSINGOFLOWRIGIDITYWORKPIECE11ANDEDMASCOMPAREDTOTHEWIREELECTRODEINSTEADOFFORMINGTHEELECTRODE,ELIMINATINGTHEMOLDINGTOOLDESIGNANDMANUFACTURINGCOSTSELECTRODEUSEDTOSHORTENTHEPRODUCTIONLEADTIMEWEDMTHEDISADVANTAGEOFLOWPRODUCTIVITY,ANDCANNOTBEBLINDHOLEMACHININGPARTSANDLADDERSURFACES22WEDMAPPLICATIONS1THETRIALOFNEWPRODUCTSNEWPRODUCTDEVELOPMENTPROCESSREQUIRESASINGLEPIECESAMPLES,USEOFWIRECUTTINGPARTSCUTOUTDIRECTLY,WITHOUTMOLDS,WHICHCANGREATLYSHORTENTHEDEVELOPMENTCYCLEOFNEWPRODUCTSANDREDUCETRIALCOSTSSUCHASSTAMPING,THEDIEISNOTEXPECTEDTOOPENCHULA,FIRSTWITHAWIRECUTTINGFORFORMINGSUCHAMODELFORSUBSEQUENTPROCESSING,BEVERIFIEDBEFOREBLANKINGDIEMANUFACTURING2PROCESSINGOFSPECIALMATERIALSCUTTINGSOMEOFTHEHIGHHARDNESS,HIGHMELTINGPOINTMETAL,THEUSEOFMACHINEPROCESSINGMETHODSISALMOSTIMPOSSIBLE,ANDECONOMICALUSEOFLINECUTTINGCANENSUREACCURACY3PROCESSINGMOLDPARTSMAINLYUSEDINEDMWIRECUTTINGDIES,EXTRUSIONDIES,PLASTICDIES,EDMELECTRODESCAVITYMOLDPROCESSING,THEEDMWIRECUTTINGSPEEDANDACCURACYOFTHERAPIDINCREASEHASREACHEDCANCOMPETEWITHTHECOORDINATESOFTHEDEGREEOFGRINDINGFOREXAMPLE,THESMALLDIE,THEMATERIALISTOOLSTEEL,INTHEPASTWITHASEPARATEMOLDANDMETHODOFCURVEGRINDINGMACHINING,EDMWIRECUTTINGNOWSWITCHTOTHEOVERALLPROCESSINGMETHODS,MANUFACTURINGCYCLECANBESHORTENED3/4TO5/4,REDUCETHECOSTOF2/3/4,WITHHIGHPRECISION,THEWORKDOESNOTREQUIRESKILLEDOPERATORSTHEREFORE,SOMEINDUSTRIALCOUNTRIESSUCHASPRECISIONGRINDINGWASHEDPROCESSHASBEENEDMANDWEDMREPLACED23WEDMAPPLICATIONAREASWEDMISMAINLYUSEDFORAVARIETYOFDIES,PLASTICMOLDS,POWDERMETALLURGYMOLDSCOMPOSEDOFTWODIMENSIONALANDTHREEDIMENSIONALRULEDSURFACEOFTHEMOLDANDPARTSCANCUTAVARIETYOFTEMPLATES,MAGNETS,SILICONSTEEL,SEMICONDUCTORMATERIALSORPRECIOUSMETALS,BUTALSOFORMICROMACHINING,SHAPEDSLOTANDTHESTANDARDSPECIMENPROCESSINGDEFECTSWIDELYUSEDINELECTRONICEQUIPMENT,PRECISIONMACHINETOOLS,LIGHTINDUSTRIAL,MILITARYANDSOON1PLANESHAPEOFTHEMETALMOLDPROCESSINGDIE,POWDERMETALLURGYMOLD,DRAWINGDIE,EXTRUSIONDIEMACHINING2THREEDIMENSIONALSHAPEOFTHEMETALMOLDPROCESSINGDIEBYTHEWITHDRAWALOFTHEDIEGROOVEMACHINING,PLASTICWITHMETALDIES,PLASTICMOLDSEPARATIONSURFACEPROCESSING3EDMPRODUCTIONOFCOMPLEXSHAPESUSINGMICROELECTRODESTHEELECTRODEPROCESS,THEGENERALPROCESSINGOFPERFORATEDELECTRODE,THEELECTRODEPROCESSWITHTAPERMOLD4TESTPRODUCTSANDPARTSPROCESSINGPROTOTYPEPARTSDIRECTLYTOPROCESSING,BATCHPROCESSINGOFSMALLVARIETYOFPARTS,SPECIALMATERIALS,SPAREPARTSPROCESSING,MATERIALS,PROCESSINGOFSPECIMENS5PROFILEGAUGEPROCESSINGMEASURINGAVARIETYOFCARDBOARDPROCESSING,THECAMANDTHETEMPLATEPROCESSING,SHAPEFORMINGCAR6MICROPROCESSINGPROCESSINGOFCHEMICALFIBERNOZZLE,SHAPEDSLOTANDNARROWCHANNELPROCESSING,STANDARDPROCESSINGDEFECTS3WEDMTECHNOLOGYSTATUSCURRENTLY,THECUTTINGSPEEDWEDMHASBEENWIDESPREADOVERTHEPAST2040MM2/MININCREASEDTO100MM2/MINABOVE,ANDSOMECANREACH260MM2/MIN,MACHININGACCURACYIS001MM,THESURFACEROUGHNESSOFTHEWORKPIECERA12525M,WHICHCANMEETTHEGENERALMOLDMACHININGANDOTHERCOMPLEXPARTSMANUFACTURINGREQUIREMENTSWITHTHEDEVELOPMENTOFSCIENCEANDTECHNOLOGY,THEMANUFACTUREOFVARIOUSPRODUCTSHAVEBECOMEINCREASINGLYDEMANDINGOFWIRECUTTINGTECHNOLOGYHASALSOPUTFORWARDHIGHERREQUIREMENTSABROADEUROPE,AMERICA,JAPAN,ETCTOGOLOWSPEEDRESEARCHANDDEVELOPMENTOFCNCWIREELECTRICDISCHARGEMACHINESTOMEETTHEREQUIREMENTSOFTHEMANUFACTURINGPROCESSTECHNOLOGY,THEUSEOFCLOSEDLOOPDIGITALDELIVERYSTRAIGHTFLOWSERVOCONTROLSYSTEMTOENSUREEXCELLENTDYNAMICPERFORMANCEANDHIGHPOSITIONINGACCURACY,PRECISIONCANBECONTROLLEDINANUMBEROFMICRONSORLESSATTHESAMETIMEWITHADIGITALADAPTIVECONTROLOFPOWERTOOLS,AUTOMATICWEARSILK,AUTOMATICREMOVABLEWASTE,SHORTCIRCUITAUTOMATICROLLBACKANDOTHERAUTOMATEDTECHNIQUES,INADDITIONTOTHEELECTRODEWIRETENSIONANDTHEWORKINGFLUIDPRESSURECANBECONTROLLEDDUETOTHEUSEOFNEWTECHNOLOGYANDFOCUSONUPDATINGTHECOMPUTERSOFTWARETECHNOLOGYANDDEVELOPMENTOFLOWSPEEDWIRECUTTINGAWAYTHEPROCESSINDICATORSHAVEREACHEDAVERYHIGHLEVELEVENIFTHEMACHININGOFCOMPLEXSHAPE,THEMAXIMUMCUTTINGSPEEDOFMORETHAN300MM2/MINSIZEPRECISIONCANREACH25MSURFACEROUGHNESSCANBEACHIEVEDRA0102MMULTIPLECUTTINGHIGHDEGREEOFAUTOMATIONOFMACHINETOOLS,PROCESSINGSTABILITY,HASBEENTHEDEVELOPMENTOFUNMANNEDMACHINING31WEDMTECHNOLOGYTRENDSWEDMDUETOLOSSOFELECTRODEWIRE,ANDPRECISIONMECHANICALPARTSOFTHESTRUCTURE,INTOTHEOPENLOOPCONTROLTOTHESYSTEM,PROCESSINGOFCHANGESINWORKINGFLUIDCONDUCTIVITY,TEMPERATUREPROCESSINGENVIRONMENTANDITSOWNPROCESSINGCHARACTERISTICSSUCHASWIRESPEEDOPERATIONFAST,MOREVIBRATIONSOURCE,GUIDEWHEELWEARLARGEANDOTHERFACTORS,MACHININGACCURACYISLIMITEDTHECURRENTSTATUSOFTHEMACHINE,TOARELATIVELYSHORTTIMEANDLOWSPEEDWIREEDMTOGOTOCOMPETEINTHEPROCESSINGPRECISION,THEDIFFICULTYISQUITELARGE,ANDRESEARCHANDDEVELOPMENTCOSTSWILLBEHIGH,THEMACHINEWILLSIGNIFICANTLYINCREASEMANUFACTURINGCOSTSFROMTHEPERSPECTIVEOFREALITYANDTHEMARKETARENOTCONSIDEREDAPPROPRIATETHEREFORE,THEDEVELOPMENTSTRATEGYWEDMWEAKNESSES,TODEVELOPMIDDLEANDLOWMACHINEBASED,SOTHATTHEMACHINETOTHEAPPROPRIATEPRECISION,GOODSTABILITYANDEASYPROCESSINGDIRECTION,TOMEETGROWINGPRODUCTIONNEEDSCURRENTLYONTHEMARKETHIGHSPEEDWIRECUTTINGAWAYTHEBIGGESTADVANTAGEISTOHAVEAGOODCOSTPERFORMANCE,THEMACHINEMUSTTAKETHISASFURTHERDEVELOPMENTOFTHEBASICSTARTINGPOINT,NOTTOOMUCHEMPHASISONPRECISIONMACHINING,ANDOVERLOOKTHEFACTORSTHATCOSTPERFORMANCEMACHINEINCONTRAVENTIONOFTHISPRINCIPLE,MACHINEMANUFACTURERSANDUSERSAREDIFFICULTTOACCEPTINTHESHORTPERIODOFTIME,SOTHATTHEPROCESSINGPERFORMANCEOFWEDMHAVEGREATLYIMPROVEDWEDMTOFURTHERDEVELOPMENT,WEMUSTGETRIDOFSBCASANUMERICALCONTROLSYSTEM,THEUSEOFNEWNCSYSTEMATPRESENT,THEREGOTHEHIGHSPEEDPCBASEDCNCWIRECUTTINGMACHINE,BUTITSMAINFUNCTIONISPROCESSINGPATHPROGRAMMING,MACHINETOOLCONTROLISFARFROMPERFECT,THEREISNOFULLUSEOFPCRESOURCESINTHEUSEOFNEWTECHNOLOGIES,NEWPROCESSESMUSTALSOATTACHIMPORTANCETOTHELAWOFWEDMPROCESSBASEDONTHOROUGHANDDETAILEDTHEORETICALANDEXPERIMENTALRESEARCH,THISISAVERYIMPORTANTPART4CONCLUSIONATPRESENT,ARTIFICIALINTELLIGENCETECHNOLOGYHASSTARTEDINTHEWEDMINTHERESEARCH,HOWEVER,THEDEPTHANDBREADTHOFRESEARCHISSTILLNOTENOUGHTHEREAREMANYASPECTSTOBESTUDIEDFURTHER1OFTHESERVOWEDMINVERTERCONTROLHASTORELYONTHEOPERATOR,SOTHEOPERATINGSTAFFSTRENGTH,MACHINEPERFORMANCEOFTHEPLAYISLIMITEDARTIFICIALINTELLIGENCEFUZZYCONTROLTECHNOLOGYISANIMPORTANTASPECTOFTECHNOLOGY,ITCANIMITATETHESKILLEDCONTROLOFMACHINETOOLS,EDMMACHINEHASBEENSUCCESSFULLYAPPLIEDINEDMWIRECUTTINGHASAGOODPROSPECT2CONCLUDEDOVERTHEYEARSTOGOWIRECUTTINGHIGHSPEEDPROCESSINGRESULTS,THEESTABLISHMENTOFAPPROPRIATEKNOWLEDGEBASEANDEXPERTSYSTEMS,REDUCINGTHEDIFFICULTYOFTHEOPERATIONOFMACHINETOOLSISESSENTIAL3ADAPTIVEPROCESSINGPARAMETERS,ETCCANMAKEADIFFERENCETHELATESTARTIFICIALINTELLIGENCETECHNOLOGYINTOTHEDEVELOPMENTOFWEDM,THEDEVELOPMENTOFHIGHSPEEDWIRECUTTINGAWAYPARTSOFTHEINTELLIGENTCONTROLANDENFORCEMENTAGENCIES,WHICHISTHECURRENTNATIONALDEVELOPMENTPRIORITIESARECONSISTENTWITHHIGHTECHINDUSTRY,HASIMPORTANTPRACTICALSIGNIFICANCE电火花线切割技术摘要随着机械制造业水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（WIRECUTELECTRICALDISCHARGEMACHINING，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（WEDMHS），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（WEDMLS），其电极丝作低速单向运动，一般走丝速度低于02M/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05MM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003035MM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隙补偿功能，同时加工凹凸两种模具时，间隙可任意调节。（6）采用乳化液或去离水的工作液，不必担心发生火灾，可以昼夜无人连续加工。（7）电火花线切割能切割加工传统方法难于加工或无法加工的高硬度、高强度、高脆性、高忍性等导电材料及半导体材料。（8）任何复杂开头的零件，只要能编制加工程序就可以进行加工，因而很适合小批零件和试制品的生产加工，加工周期短，应用灵活。（9）采用四轴联动，可加工上，下面异形体，形状扭曲曲面体，变锥度和球形等零件。10加工过程中，工具与工件不直接接触，不存在显著的切削力，有利加工低刚度工件。11与电火花成形相比，以线电极代替成形电极，省去了成形工具电极的设计和制造费用，缩短了生产准备时间。电火花线切割加工的缺点是生产率低，且不能加工盲孔类零件和阶梯表面。电火花线切割加工的应用（1）试制新产品在新产品开发过程中需要单件的样品，使用线切割直接切割出零件，无需模具，这样可以大大缩短新产品的开发周期并降低试制成本。如在冲压生产时，未开出落料模时，先用线切割加工的样板进行成形等后续加工，得到验证后再制造落料模。（2）加工特殊材料切割某些高硬度，高熔点的金属时，使用机加工的方法几乎是不可能的，而采用线切割加工既经济又能保证精度。（3）加工模具零件电火花线切割加工主要应用于冲模、挤压模、塑料模、电火花型腔模的电极加工等，由于电火花线切割加工速度和精度的迅速提高，目前已达到可与坐标磨床相竞争的程度。例如，中小型冲模，材料为模具钢，过去用分开模和曲线磨削的方法加工，现在改用电火花线切割整体加工的方法，制造周期可缩短3/45/4，成本降低2/33/4，配合精度高，不需要熟练的操作工作。因此，一些工业发达国家的精密冲的磨削等工序，已被电火花和电火花线切割加工所代替。电火花线切割加工的应用领域电火花线切割主要用于各种冲模、塑料模、粉末冶金模等二维及三维直纹面组成的模具及零件。也可切割各种样板、磁钢、硅钢片、半导体材料或贵重金属，还可进行微细加工，异形槽和试件上标准缺陷的加工。广泛用于电子仪器、精密机床、轻工、军工等。（1）平面形状的金属模