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目 錄
中文摘要 ·································································1
英文摘要 ·································································2
一、引言 ································································3
1.1 題研究的目的和意義················································3
1.2 本設(shè)計(jì)國內(nèi)外研究歷史與現(xiàn)狀 ·······································4
1.3 本設(shè)計(jì)擬解決的關(guān)鍵問題和研究方法··································5
1.4 電火花成型加工特點(diǎn)和適用范圍······································5
二、 電火花成型機(jī)床總體結(jié)構(gòu)設(shè)計(jì) ·····································8
2.1 電火花成型機(jī)的結(jié)構(gòu) 形式···········································8
2.2 電火花成型機(jī)結(jié)構(gòu)設(shè)計(jì)···············································9
三、 主軸系統(tǒng)設(shè)計(jì)······················································13
3.1 主軸系統(tǒng)設(shè)計(jì)方案··················································13
3.2 電機(jī)的選擇 ·······················································14
3.3 同步齒形帶設(shè)計(jì) ···················································19
3.4 滾珠絲桿副的設(shè)計(jì)··················································22
3.5 直線導(dǎo)軌的設(shè)計(jì) ···················································27
四、工作臺設(shè)計(jì) ························································29
五、十字滑座設(shè)計(jì)······················································34
六、電極夾頭設(shè)計(jì)·······················································37
七、機(jī)床潤滑系統(tǒng)設(shè)計(jì) ·················································40
八、工作液循環(huán)裝置結(jié)構(gòu)設(shè)計(jì) ··········································42
參考文獻(xiàn)·······························································.45
謝辭 ···································································46
附錄·····································································47
翻譯··························································52
摘 要： 介紹了電火花成型機(jī)床的加工原理、特點(diǎn)及其發(fā)展歷程：它是通過脈沖直流電源不斷產(chǎn)生火花放電來去除工件材料，且在工件與工具之間有絕緣液體介質(zhì)。
分析并設(shè)計(jì)了電火花成型機(jī)床結(jié)構(gòu)系統(tǒng)。機(jī)床總體布局為單柱立式，主軸采用步進(jìn)電機(jī)拖動滾珠絲桿完成升降，利用步進(jìn)電機(jī)多級可變細(xì)分技術(shù)，實(shí)現(xiàn)伺服系統(tǒng)的變頻、變步距雙重伺服調(diào)節(jié)，提高系統(tǒng)的跟蹤能力和穩(wěn)定性。進(jìn)給系統(tǒng)采用滾珠絲桿和十字滑座實(shí)現(xiàn)工作臺的橫向、縱向移動，運(yùn)動平穩(wěn)。
電火花成形加工要在加工精度、加工效率、加工范圍等方面取得重大突破，一個(gè)重要的發(fā)展方向就是對機(jī)床成形運(yùn)動方式的創(chuàng)新和多樣化。本課題的研究，是對電火花成型加工發(fā)展方向的一次有益嘗試，通過改進(jìn)電火花加工機(jī)床的伺服系統(tǒng)、控制系統(tǒng)、機(jī)床結(jié)構(gòu)等，在保證加工精度的前提下提高了加工效率；通過開放式的控制系統(tǒng)，提高了電火花成型加工過程的自動化。
關(guān)鍵詞：電火花； 主軸； 滾珠絲桿； 十字滑座； V型導(dǎo)軌
Abstract： The processing principles, characteristics and development process of the EDM machine by author is introdunced in this paper. It removes material with repetitive spark discharges from a pulsating DC power supply, with a dielectric flowing between the work piece and the tool.
Analysis and design the system of structure for EDM machine . Machine overall layout as a single vertical column, 3-axis; Stepper motor is used in the machine tool to drive the ball screew up and down directly,the control system of the machinetool acapt divided dreving technique of step motor,and realizes dual regulations with changing feed step and changing feed frequency ,this improves its tracking ablity and stability. Feed system uses Ball Screw and the cross slide take the table move on the horizontal and vertical , smooth motion.
EDM should be in the processing accuracy, processing efficiency, processing and other aspects of the scope of a major breakthrough, an important direction of development is the right tool forming movement pattern of innovation and diversification. The study of this topic is a direction of development of EDM machining a useful attempt, by improving EDM servo systems, control systems, machine tool structure, guarantee the processing precision under the premise of improving the processing efficiency; through open the control system to improve the EDM process automation.
Keywords: EDM；main spindle；ball screw；Cross slide；V-shaped guideways
一 引言
精密數(shù)控電火花成型機(jī)是為了適應(yīng)工業(yè)飛速發(fā)展，尤其是模具制造工業(yè)發(fā)展而設(shè)計(jì)的新型機(jī)床，有較高的加工工藝指標(biāo)，應(yīng)用廣泛，用于電機(jī)、儀表、電器、汽車制造、宇航、家電、輕上、軍工等多種行業(yè)中的模具制造加工?？梢约庸じ鞣N中小型沖裁模(落料模、復(fù)合模和級進(jìn)模)，型腔模(精密壓鑄、壓延、塑料、玻璃制品、粉末冶金和膠木等)，各種超硬度材料，異型曲面零件，坐標(biāo)孔零件及成型零件。機(jī)床可以加工如直徑為0．1mm以上的孔徑和0．2mm以上的窄縫，切割各種硬質(zhì)臺金和取折斷工具等，能對碳素鋼、工具鋼、淬火鋼、硬質(zhì)合金鋼以及其他高硬度金屬材料進(jìn)行放電加工，是加工復(fù)雜模具和復(fù)雜零件的理想設(shè)備。數(shù)控電火花成型機(jī)也是專門對導(dǎo)電材料進(jìn)行標(biāo)準(zhǔn)化電火花加工而設(shè)計(jì)的。它還可以實(shí)現(xiàn)無人操作自動加工，大幅度提高生產(chǎn)效率和經(jīng)濟(jì)效益。所以說，數(shù)控電火花成型機(jī)床的問世，對傳統(tǒng)的機(jī)加工技術(shù)產(chǎn)生了很大的沖擊，也給制造行業(yè)帶來了新的發(fā)展和進(jìn)步。
隨著電子技術(shù)、計(jì)算機(jī)技術(shù)、精密模具制造技術(shù)、材料科學(xué)等尖端科學(xué)技術(shù)的飛速發(fā)展，對零件的精度、性能、壽命的要求越來越高。因此在設(shè)計(jì)上采用了許多新技術(shù)、新材料、新結(jié)構(gòu)，導(dǎo)致零件的結(jié)構(gòu)、形狀復(fù)雜，如薄壁深孔零件，這類零件出于精度、壽命等因素考慮，常采用高溫合金、硬質(zhì)合金、耐熱鋼淬火鋼等材料，且加工精度、表面粗糙度要求高，傳統(tǒng)的機(jī)械加工方法實(shí)現(xiàn)困難、成本高。作為基礎(chǔ)工業(yè)的機(jī)械制造業(yè)，其發(fā)展的核心問題之一就是如何進(jìn)一步提高機(jī)械加工的精度和質(zhì)量，同時(shí)降低經(jīng)濟(jì)成本。
1.1 題研究的目的和意義
隨著社會的進(jìn)步和科學(xué)技術(shù)的發(fā)展，在機(jī)加工領(lǐng)域出現(xiàn)了一些硬度高難于用傳統(tǒng)機(jī)加工方法加工的新材料。于是在工藝上要求出現(xiàn)一種適應(yīng)加工需求的加工機(jī)械。電火花成型機(jī)正是適應(yīng)了這種需求，并且電火花成型機(jī)作為刀具與工件非接觸式加工的機(jī)床，克服了以往切削加工機(jī)床的局限。
本課題的研究意義：本課題根據(jù)企業(yè)的實(shí)際生產(chǎn)需要，通過該課題的研究，將電火花加工技術(shù)及加工機(jī)床的最新發(fā)展成果應(yīng)用于企業(yè)的生產(chǎn)實(shí)際，設(shè)計(jì)的機(jī)床具有自動進(jìn)給功能，既實(shí)現(xiàn)了研究成果向生產(chǎn)力的轉(zhuǎn)化，又為企業(yè)節(jié)約了大量的資金，具有重大的經(jīng)濟(jì)價(jià)值和現(xiàn)實(shí)意義。
本課題的主要目的：本課題在對電火花成型機(jī)原理分析研究基礎(chǔ)上，研究設(shè)計(jì)機(jī)床的結(jié)構(gòu)系統(tǒng)、驅(qū)動控制、結(jié)構(gòu)的動態(tài)分析與優(yōu)化等。其主要內(nèi)容如下：1、了解電火花成型機(jī)的機(jī)械結(jié)構(gòu)系統(tǒng)，根據(jù)零件加工要求，設(shè)計(jì)機(jī)床整體結(jié)構(gòu)；2、設(shè)計(jì)機(jī)床的進(jìn)給系統(tǒng)，優(yōu)化系統(tǒng)結(jié)構(gòu)；3、對機(jī)床運(yùn)動進(jìn)行運(yùn)動學(xué)分析和參數(shù)優(yōu)化。4、對進(jìn)給系統(tǒng)進(jìn)行控制部分設(shè)計(jì)。
1.2國內(nèi)外研究歷史與現(xiàn)狀
電火花成型機(jī)在20世紀(jì)40年代開始研究并逐步應(yīng)用于生產(chǎn)，最初出現(xiàn)的只可單軸進(jìn)給的單立柱機(jī)床。隨后出現(xiàn)了多軸聯(lián)動，多立柱的電火花成型機(jī)。異形小孔的加工機(jī)床的出現(xiàn)也是電火花成型機(jī)發(fā)展史上的一大進(jìn)步，例如D703型高速電火花夾攻小孔機(jī)床。SP1-30鏡面電火花機(jī)采用的松下伺服系統(tǒng)，表面粗糙度可達(dá)Ra0.1um,HE350-CNC雙頭機(jī)電火花成型機(jī)為我國自主研發(fā)，加工效率成倍提高。但就總體而言，我國在電火花加工領(lǐng)域同日本等國際先進(jìn)水平還有一定差距。