基于电极切向旋转进给法的低刚度锥杆类零件精密电火花加工

摘要

This paper presents a precise EDM method for processing cone rod parts with low stiffness, which is based on a rotating disc electrode with tangent feeding. We introduced the method of designing the disc electrode based on equal wear principle. A group of full factorial experiments was implemented to investigate the effects of peak current, pulse duration and duty ratio on work piece material removal rate (MRR), relative tool wear ratio (TWR) and surface roughness (SR). Then optimized EDM parameters are used in processing of cone rod parts. And the processing feedback rods are of properties of high conformance, good surface quality, and short processing time. The test results show that the EDM method based on rotating disc electrode has significant advantages in improving reliability of processing technolo-gy of cone rods with low stiffness, efficiency of machining parts and utilization rate of electrode.%提出了基于圆盘电极切向旋转进给法的低刚度锥杆类零件的电火花精密加工方法。首先介绍了基于等厚损耗原则的圆盘电极设计原理，进而通过电火花加工工艺的三因素全因子实验考察了峰值电流、脉宽、占空比对工件材料去除率（ MRR ）、相对电极损耗率（ TWR ）和表面粗糙度（ SR ）的影响，并对电火花加工工艺参数进行优化从而应用于锥杆类零件的加工。加工出的反馈杆性能一致性高、表面质量好，加工时间短，试验结果表明基于圆盘电极切向旋转进给法的电火花加工工艺对提高低刚度锥杆的加工工艺的可靠性和加工效率、提高电极利用率方面有较大优势。