关于提高电火花线切割加工效率的工艺数据处理系统研究
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摘要
电火花加工技术等特种加工方法对于某些难加工材料工件的加工，尤其是在窄槽、深腔、微细、复杂形状等的加工领域，表现出了无与伦比的优势。目前，国内高速走丝电火花线切割机不具有工艺数据库系统和自动优选加工参数功能，不利于提高加工效率、加工质量。
因此，本文提出了建立线切割加工工艺数据库并应用EBP人工神经网络技术优化处理加工参数的的论题。论文在创建电火花线切割加工过程工艺数据库的基础上，结合国内高速走丝线切割机加工操作现状，来阐述应用人工神经网络数据处理方法进行电加工参数优化选择、匹配组合的技术，并据此对脉冲电源进行参数化平滑调节的数控改进设计；最后简要讨论了数控脉冲参数平滑调节在放电加工过程参数优化系统中的应用，体现了系统设计对提高加工效率需求的有效性。这就使得操作者能够根据不同的加工需求迅速、高效、经济地抉择面向应用的工艺加工过程，提高了系统的可伸缩性、可移植性、可维护性。
本论文的在结构安排、各章节的概要内容如下：
第一章 绪论，讨论论文的研究背景、状况、意义和主要内容。说明线切割机工艺数据库和自动优选加工参数系统的基本特点和要求。
第二章 根据工艺参数优化处理的系统结构，创建电火花线切割加工工艺数据库，完成了应用系统的初步框架设计。
第三章 研究应用EBP人工神经网络方法对线切割加工参数和工艺效果之间的复杂函数关系建模，找到了能反映机床的工艺规律的加工过程参数预测模型，能够较为成功地预测出指定工艺条件下的加工速度和表面粗糙度。
第四章 在参数优化选取的前提下，进行并联电容型脉冲电源标准总线化数控改进设计，以达到加工过程优化调节、控制的目的。
本文的最后一章对研究进行了概括和总结，并对未来研究的进一步深化做出了展望。
EDM and other non-traditional machining technology are super for some parts manufacturing of some materials that are not easy to deal with, especially in the field of the machining requirements about slots, deep caves, micro-small and complex shapes. At present, the automation degree and processing DBA system of our high speed EDM equipments are very lagged, which is no good to give high manufacturing efficiency and improve manufacturing precision.
That is why this paper give the issue to build the processing system for WEDM equipment based on the most advanced intelligent tech. Through the modification and designing of pulse source with paralleled capacity, combined the open designing for the different function units of the device based on network, this paper discusses the application of the designed adjustment and control system for pulse parameters in the optimal control systems about discharging manufacturing course at the function rebuilt requirements of deferent customers easily and freely, and talk about the applying for the market about the designed equipment. It aims at the high speed, high efficiency, costly building of different technology control systems oriented the application for the variable manufacturing requirements of all kind of related users. It could work easily for the new built system with the new application software based on the original hardware NC platform to give some desirable abilities of the system like flexibility, opening, replacement and maintaining.
The architecture of this paper and contents of every chapter as follows:
In chapter 1, the paper discusses the backdrop, status, meaning and main contents of this dissertation. And then give the basis points of open data processing system and its requirements.
In chapter 2, the paper expatiates the common parts between DBA and data processing system operation platform. And then analyzes the feasibility and optimum aspects to build parameter dealing system for WEDM and others related units.
In chapter 3, the paper focuses on the development of the syetem architecture for processing data dealing of WEDM based on ANN. Through the reconstruction and design of the pulse source with paralleled capacity to transfer it as an open function unit, the paper expatiates the construction of all the systemic function parts and method of realization. At last, the paper analyzes the main system operation software in a whole.
In chapter 4, the paper introduces new designing for pulse source and its function of the WEDM with data optimizing system and then validates the function configuration of operation adjustment and control processing as the required of different users.
In chapter 5, the paper summarizes the work of the dissertation; the shortcoming and future work are also sketched out.
因此，本文提出了建立线切割加工工艺数据库并应用EBP人工神经网络技术优化处理加工参数的的论题。论文在创建电火花线切割加工过程工艺数据库的基础上，结合国内高速走丝线切割机加工操作现状，来阐述应用人工神经网络数据处理方法进行电加工参数优化选择、匹配组合的技术，并据此对脉冲电源进行参数化平滑调节的数控改进设计；最后简要讨论了数控脉冲参数平滑调节在放电加工过程参数优化系统中的应用，体现了系统设计对提高加工效率需求的有效性。这就使得操作者能够根据不同的加工需求迅速、高效、经济地抉择面向应用的工艺加工过程，提高了系统的可伸缩性、可移植性、可维护性。
本论文的在结构安排、各章节的概要内容如下：
第一章 绪论，讨论论文的研究背景、状况、意义和主要内容。说明线切割机工艺数据库和自动优选加工参数系统的基本特点和要求。
第二章 根据工艺参数优化处理的系统结构，创建电火花线切割加工工艺数据库，完成了应用系统的初步框架设计。
第三章 研究应用EBP人工神经网络方法对线切割加工参数和工艺效果之间的复杂函数关系建模，找到了能反映机床的工艺规律的加工过程参数预测模型，能够较为成功地预测出指定工艺条件下的加工速度和表面粗糙度。
第四章 在参数优化选取的前提下，进行并联电容型脉冲电源标准总线化数控改进设计，以达到加工过程优化调节、控制的目的。
本文的最后一章对研究进行了概括和总结，并对未来研究的进一步深化做出了展望。
EDM and other non-traditional machining technology are super for some parts manufacturing of some materials that are not easy to deal with, especially in the field of the machining requirements about slots, deep caves, micro-small and complex shapes. At present, the automation degree and processing DBA system of our high speed EDM equipments are very lagged, which is no good to give high manufacturing efficiency and improve manufacturing precision.
That is why this paper give the issue to build the processing system for WEDM equipment based on the most advanced intelligent tech. Through the modification and designing of pulse source with paralleled capacity, combined the open designing for the different function units of the device based on network, this paper discusses the application of the designed adjustment and control system for pulse parameters in the optimal control systems about discharging manufacturing course at the function rebuilt requirements of deferent customers easily and freely, and talk about the applying for the market about the designed equipment. It aims at the high speed, high efficiency, costly building of different technology control systems oriented the application for the variable manufacturing requirements of all kind of related users. It could work easily for the new built system with the new application software based on the original hardware NC platform to give some desirable abilities of the system like flexibility, opening, replacement and maintaining.
The architecture of this paper and contents of every chapter as follows:
In chapter 1, the paper discusses the backdrop, status, meaning and main contents of this dissertation. And then give the basis points of open data processing system and its requirements.
In chapter 2, the paper expatiates the common parts between DBA and data processing system operation platform. And then analyzes the feasibility and optimum aspects to build parameter dealing system for WEDM and others related units.
In chapter 3, the paper focuses on the development of the syetem architecture for processing data dealing of WEDM based on ANN. Through the reconstruction and design of the pulse source with paralleled capacity to transfer it as an open function unit, the paper expatiates the construction of all the systemic function parts and method of realization. At last, the paper analyzes the main system operation software in a whole.
In chapter 4, the paper introduces new designing for pulse source and its function of the WEDM with data optimizing system and then validates the function configuration of operation adjustment and control processing as the required of different users.
In chapter 5, the paper summarizes the work of the dissertation; the shortcoming and future work are also sketched out.
引文
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7. Brain A Malloy、Bin Chen, Exploiting an Object-Oriented Simulation Tool to Model a PCS Network, Simulation, 1998, 6
8. Anupam V、Bajaj C L, Shastra: multimedia collaborative design environment, IEEE Multimedia, Sunmer, 2001, 20(1)
9. Yoram Koern, Real-time Open Control Architecture and system performance, Annals of the CIRP, 1996,45(1)
10. Harris J H、Powell S, An algotithm for optimal placement in reliable serial lines, IIE transactins, 1999, 31
11. John Vince, Virtual reality systems, Addsion Wesley publishing company, 1997
12. Ulusoy G, Simultaneous scheduling of machines and automated guided vehicles, Computers and Operation Research, 1997, 24(4)
13. Ka J F, A neural network approach for on-line monitoring of the EDM, Journal of Materials Processing Technology, 1997,69(9)
14. HUI K C, Geometric aspects of the mouldability of parts, Computer-Aided Design, 1997,29(3)
15. Masanori Kunieda, High precision finish cutting by dry WEDM, Annals of the CIRP, 2001, 50(1)
16. Lau H, New role of Intranet/Internet Technology for Manufacturing, Engineering with Computers, 1998,14(2)
17. M. Mitsuishi、S. Warisawa, Development of an intelligent high-speed machining
center, Annals of the CIRP, 2001,50(1)
18. Markus Thannhuber、Mitchell M. Tseng, An autopoietic approach for building knowledge management system in manufacturing enterprises, Annals of the CIRP, 2001, 50(1)
19. K Mallidi、P Paganelli, Process modeling in small-medium enterprise networks, Computers in industry, 1999,38(2)
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21. James H, Web-based net management is coming, Data Communications, 1997,26(14)
22．楼乐明、李明辉、彭颖红，利用神经网络建立电火花加工工艺模型，中国机械工程，2001，12(4)
23．杨宪惠，现场总线技术及其应用，清华大学出版社，1999版
24．李明辉，电火花加工理论基础，北京：国防工业出版社，1989版
25．胡石玉，模具制造技术，东南大学出版社，1997版
26．刘晋春、赵家齐，特种加工，机械工业出版社，1998版
27．吴秋峰，自动化系统计算机网络，机械工业出版社，2001版
28．吴崇峰，实用注塑模CAD/CAE/CAM技术，中国轻工业出版社，2000版
29．吴重光，仿真技术，化学工业出版社，2000版
30．于海生等，微型计算机控制技术，清华大学出版社，1999版
31．曹光宇、狄士春、赵万生，电火花加工过程模糊控制系统的参数选取与算法设计，电加工，1998，3
32．曹化工、杨曼红，基于对象Petri网的工作流过程定义，计算机辅助设计与图形学学报，2001，1
33．汪盛，基于组件技术的模型管理，计算机工程，2001，1
34．周祖德、魏仁选、陈幼平，开放式控制系统的现状、趋势和对策，中国机械工程，2001，5(2)
35．吴巨红、罗铁庚、龚正虎，群集管理系统的作业调度算法研究，计算机工程，2001，2
36．韩强、赵万生、狄士春，电火花加工放电状态稳定性研究，电加工，1999，2
37．王怿忻、林成德，面向对象的离散事件系统仿真软件的多线程实现，计算机工程与应用，2001，17
38．隋杰、于华等，基于工作流的模具敏捷制造过程的Petri网建模，计算机集成制造系统----CIMS，2001，8
39．董志斌、吴启迪等，面向对象的过程仿真技术及其支撑环境，计算机集成制造系统----CIMS，2001，9
40．王振华、朱国力，基于现场总线的新型开放式数控系统研究，中国机械工程，2001，6(4)
41．中国机械工程学会电加工学会，电火花线切割加工，哈尔滨工业大学出版社，1989版
42．苑延闽、定海，面向对象分析OOA和设计，清华大学出版社，2001版
43．霍孟友、王晓晨、艾兴，电火花加工数控系统状态监控的实现，电加工，1998，6
44．王蔚岷、赵万生、白基成、郑炜、迟玉平、刘晋春，电火花加工放电状态检测及微机自适应控制脉冲电源，电加工，1988，2
45．钟约先、林亨，机械系统计算机控制，清华大学出版社，2000版
46．郇极，开放式数控系统的数字伺服接口和通信协议，中国机械工程，1998，9(5)
47．李红兵、张东摩，虚拟环境的系统设计方法及计算机模型研究，计算机学报，1999，22(3)
48．袁颖河、吴智铭，FMS-AGV传输系统自学习调度方法，上海交通大学学报，1998，32(6)
49．冯勇等，现代计算机数控系统，机械工业出版社，1999版
50．樊东平、刘又诚，自适应应用软件系统构架建模与系统建造方法，计算机工程与应用，2001，12
51．刘铁铭、范玉顺，基于工作流的企业过程的建模和仿真技术研究，清华大学学报(自然科学版)，2000，40(1)
52．刘利峰、王敏杰，面向模具制造的多功能DNC通信系统开发，模具工业，2001，4
53．李健、刘飞，基于网络的先进制造技术，中国机械工程，2001，12(2)
54．杨庆等，企业级工控实时数据库研究与实现，计算机工程与应用，2001，13
55．孙自安、张莉，企业过程监控系统的研究与设计，计算机工程与应用，2001，12
56．王宇晗、吴祖育、陆志强、李宇昊，开放式控制器对数控机床低成本改造的策略，机械设计与研究，2000，8
57．张大卫、袁大春，基于填充曲线刀具路径的数据铣削过程物理仿真，中国机械工程，2001，12(4)
58．唐志玉等，塑料制品设计师指南，北京：国防工业出版社，1993
59．郭阳、李思昆等，基于集成框架的虚拟原型异构建模与仿真，计算机工程与科学，2001，23(1)
2. Zeigler B P, Object-Oriented Simulation with Hierachical, Modular models, London: Academic Press, 1998
3. Altintas Y,A Hierachical Open Architecture CNC System for Machine Tools, Annals of the CIRP, 1999,43(1)
4. Iwata K、Onosato M、Oski S, A modeling and simulation architecture for virtual manufacturing systems, Annals of the CIRP, 1995,44(1)
5. Mili h, Mili F, Mili A, Reusing software: Issues and Research Directions, IEEE Transaction on Software Engineering, 2000, 21(6)
6. Oren TI, Zeiglr, Concepts for Advanced Simulation Methodology, Simulation, 1997(8)
7. Brain A Malloy、Bin Chen, Exploiting an Object-Oriented Simulation Tool to Model a PCS Network, Simulation, 1998, 6
8. Anupam V、Bajaj C L, Shastra: multimedia collaborative design environment, IEEE Multimedia, Sunmer, 2001, 20(1)
9. Yoram Koern, Real-time Open Control Architecture and system performance, Annals of the CIRP, 1996,45(1)
10. Harris J H、Powell S, An algotithm for optimal placement in reliable serial lines, IIE transactins, 1999, 31
11. John Vince, Virtual reality systems, Addsion Wesley publishing company, 1997
12. Ulusoy G, Simultaneous scheduling of machines and automated guided vehicles, Computers and Operation Research, 1997, 24(4)
13. Ka J F, A neural network approach for on-line monitoring of the EDM, Journal of Materials Processing Technology, 1997,69(9)
14. HUI K C, Geometric aspects of the mouldability of parts, Computer-Aided Design, 1997,29(3)
15. Masanori Kunieda, High precision finish cutting by dry WEDM, Annals of the CIRP, 2001, 50(1)
16. Lau H, New role of Intranet/Internet Technology for Manufacturing, Engineering with Computers, 1998,14(2)
17. M. Mitsuishi、S. Warisawa, Development of an intelligent high-speed machining
center, Annals of the CIRP, 2001,50(1)
18. Markus Thannhuber、Mitchell M. Tseng, An autopoietic approach for building knowledge management system in manufacturing enterprises, Annals of the CIRP, 2001, 50(1)
19. K Mallidi、P Paganelli, Process modeling in small-medium enterprise networks, Computers in industry, 1999,38(2)
20. Hollingsworth D, Workflow management coalition: The Workflow Reference Model, Document number WfMC-TC00-1003, Brussels, 1994.
21. James H, Web-based net management is coming, Data Communications, 1997,26(14)
22．楼乐明、李明辉、彭颖红，利用神经网络建立电火花加工工艺模型，中国机械工程，2001，12(4)
23．杨宪惠，现场总线技术及其应用，清华大学出版社，1999版
24．李明辉，电火花加工理论基础，北京：国防工业出版社，1989版
25．胡石玉，模具制造技术，东南大学出版社，1997版
26．刘晋春、赵家齐，特种加工，机械工业出版社，1998版
27．吴秋峰，自动化系统计算机网络，机械工业出版社，2001版
28．吴崇峰，实用注塑模CAD/CAE/CAM技术，中国轻工业出版社，2000版
29．吴重光，仿真技术，化学工业出版社，2000版
30．于海生等，微型计算机控制技术，清华大学出版社，1999版
31．曹光宇、狄士春、赵万生，电火花加工过程模糊控制系统的参数选取与算法设计，电加工，1998，3
32．曹化工、杨曼红，基于对象Petri网的工作流过程定义，计算机辅助设计与图形学学报，2001，1
33．汪盛，基于组件技术的模型管理，计算机工程，2001，1
34．周祖德、魏仁选、陈幼平，开放式控制系统的现状、趋势和对策，中国机械工程，2001，5(2)
35．吴巨红、罗铁庚、龚正虎，群集管理系统的作业调度算法研究，计算机工程，2001，2
36．韩强、赵万生、狄士春，电火花加工放电状态稳定性研究，电加工，1999，2
37．王怿忻、林成德，面向对象的离散事件系统仿真软件的多线程实现，计算机工程与应用，2001，17
38．隋杰、于华等，基于工作流的模具敏捷制造过程的Petri网建模，计算机集成制造系统----CIMS，2001，8
39．董志斌、吴启迪等，面向对象的过程仿真技术及其支撑环境，计算机集成制造系统----CIMS，2001，9
40．王振华、朱国力，基于现场总线的新型开放式数控系统研究，中国机械工程，2001，6(4)
41．中国机械工程学会电加工学会，电火花线切割加工，哈尔滨工业大学出版社，1989版
42．苑延闽、定海，面向对象分析OOA和设计，清华大学出版社，2001版
43．霍孟友、王晓晨、艾兴，电火花加工数控系统状态监控的实现，电加工，1998，6
44．王蔚岷、赵万生、白基成、郑炜、迟玉平、刘晋春，电火花加工放电状态检测及微机自适应控制脉冲电源，电加工，1988，2
45．钟约先、林亨，机械系统计算机控制，清华大学出版社，2000版
46．郇极，开放式数控系统的数字伺服接口和通信协议，中国机械工程，1998，9(5)
47．李红兵、张东摩，虚拟环境的系统设计方法及计算机模型研究，计算机学报，1999，22(3)
48．袁颖河、吴智铭，FMS-AGV传输系统自学习调度方法，上海交通大学学报，1998，32(6)
49．冯勇等，现代计算机数控系统，机械工业出版社，1999版
50．樊东平、刘又诚，自适应应用软件系统构架建模与系统建造方法，计算机工程与应用，2001，12
51．刘铁铭、范玉顺，基于工作流的企业过程的建模和仿真技术研究，清华大学学报(自然科学版)，2000，40(1)
52．刘利峰、王敏杰，面向模具制造的多功能DNC通信系统开发，模具工业，2001，4
53．李健、刘飞，基于网络的先进制造技术，中国机械工程，2001，12(2)
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