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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 本設計國內(nèi)外研究歷史與現(xiàn)狀 ·······································4
1.3 本設計擬解決的關鍵問題和研究方法··································5
1.4 電火花成型加工特點和適用范圍······································5
二、 電火花成型機床總體結構設計 ·····································8
2.1 電火花成型機的結構 形式···········································8
2.2 電火花成型機結構設計···············································9
三、 主軸系統(tǒng)設計······················································13
3.1 主軸系統(tǒng)設計方案··················································13
3.2 電機的選擇 ·······················································14
3.3 同步齒形帶設計 ···················································19
3.4 滾珠絲桿副的設計··················································22
3.5 直線導軌的設計 ···················································27
四、工作臺設計 ························································29
五、十字滑座設計······················································34
六、電極夾頭設計·······················································37
七、機床潤滑系統(tǒng)設計 ·················································40
八、工作液循環(huán)裝置結構設計 ··········································42
參考文獻·······························································.45
謝辭 ···································································46
附錄·····································································47
翻譯··························································52
摘 要： 介紹了電火花成型機床的加工原理、特點及其發(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)。
分析并設計了電火花成型機床結構系統(tǒng)。機床總體布局為單柱立式，主軸采用步進電機拖動滾珠絲桿完成升降，利用步進電機多級可變細分技術，實現(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。進給系統(tǒng)采用滾珠絲桿和十字滑座實現(xiàn)工作臺的橫向、縱向移動，運動平穩(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，一個重要的發(fā)展方向就是對機床成形運動方式的創(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，通過改進電火花加工機床的伺服系統(tǒng)、控制系統(tǒng)、機床結構等，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。
關鍵詞：電火花； 主軸； 滾珠絲桿； 十字滑座； V型導軌
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)控電火花成型機是為了適應工業(yè)飛速發(fā)展，尤其是模具制造工業(yè)發(fā)展而設計的新型機床，有較高的加工工藝指標，應用廣泛，用于電機、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。可以加工各種中小型沖裁模(落料模、復合模和級進模)，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，坐標孔零件及成型零件。機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行放電加工，是加工復雜模具和復雜零件的理想設備。數(shù)控電火花成型機也是專門對導電材料進行標準化電火花加工而設計的。它還可以實現(xiàn)無人操作自動加工，大幅度提高生產(chǎn)效率和經(jīng)濟效益。所以說，數(shù)控電火花成型機床的問世，對傳統(tǒng)的機加工技術產(chǎn)生了很大的沖擊，也給制造行業(yè)帶來了新的發(fā)展和進步。
隨著電子技術、計算機技術、精密模具制造技術、材料科學等尖端科學技術的飛速發(fā)展，對零件的精度、性能、壽命的要求越來越高。因此在設計上采用了許多新技術、新材料、新結構，導致零件的結構、形狀復雜，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)的機械加工方法實現(xiàn)困難、成本高。作為基礎工業(yè)的機械制造業(yè)，其發(fā)展的核心問題之一就是如何進一步提高機械加工的精度和質(zhì)量，同時降低經(jīng)濟成本。
1.1 題研究的目的和意義
隨著社會的進步和科學技術的發(fā)展，在機加工領域出現(xiàn)了一些硬度高難于用傳統(tǒng)機加工方法加工的新材料。于是在工藝上要求出現(xiàn)一種適應加工需求的加工機械。電火花成型機正是適應了這種需求，并且電火花成型機作為刀具與工件非接觸式加工的機床，克服了以往切削加工機床的局限。
本課題的研究意義：本課題根據(jù)企業(yè)的實際生產(chǎn)需要，通過該課題的研究，將電火花加工技術及加工機床的最新發(fā)展成果應用于企業(yè)的生產(chǎn)實際，設計的機床具有自動進給功能，既實現(xiàn)了研究成果向生產(chǎn)力的轉化，又為企業(yè)節(jié)約了大量的資金，具有重大的經(jīng)濟價值和現(xiàn)實意義。
本課題的主要目的：本課題在對電火花成型機原理分析研究基礎上，研究設計機床的結構系統(tǒng)、驅(qū)動控制、結構的動態(tài)分析與優(yōu)化等。其主要內(nèi)容如下：1、了解電火花成型機的機械結構系統(tǒng)，根據(jù)零件加工要求，設計機床整體結構；2、設計機床的進給系統(tǒng)，優(yōu)化系統(tǒng)結構；3、對機床運動進行運動學分析和參數(shù)優(yōu)化。4、對進給系統(tǒng)進行控制部分設計。
1.2國內(nèi)外研究歷史與現(xiàn)狀
電火花成型機在20世紀40年代開始研究并逐步應用于生產(chǎn)，最初出現(xiàn)的只可單軸進給的單立柱機床。隨后出現(xiàn)了多軸聯(lián)動，多立柱的電火花成型機。異形小孔的加工機床的出現(xiàn)也是電火花成型機發(fā)展史上的一大進步，例如D703型高速電火花夾攻小孔機床。SP1-30鏡面電火花機采用的松下伺服系統(tǒng)，表面粗糙度可達Ra0.1um,HE350-CNC雙頭機電火花成型機為我國自主研發(fā)，加工效率成倍提高。但就總體而言，我國在電火花加工領域同日本等國際先進水平還有一定差距。