比例-积分-微分压力控制的放电雾化烧蚀磨削加工方法
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摘要
为了提高电火花放电雾化烧蚀加工效率,以烧结金刚石材料作为加工电极,利用金刚石颗粒的磨削作用实现了高效雾化烧蚀与机械磨削的复合加工.其中,通过测量加工过程中金刚石颗粒与工件之间的机械磨削作用力,实现了基于压力信号检测的伺服控制,以保证金刚石颗粒的磨削作用,并采用反比例、模糊和比例-积分-微分(PID)压力控制方法来维持加工过程中的压力稳定性.同时,以高强钢Q420C为加工对象进行了3组加工效率对比试验.结果表明:采用PID压力控制方法,在30min的加工时间内所得加工深度可达14.5mm,最大压力在1.0N以内,其加工效率和加工稳定性优于其他2种控制方法.
To improve the efficiency of electrical discharge machining(EDM)ablation,this paper uses a sintered diamond electrode as the machining electrode,making use of grinding action of diamond particles,to achieve machining combined with high efficiency ablation and mechanical grinding.In the study,through gathering mechanical grinding force during machining,a control method based on force signal is proposed to ensure diamond particles grinding.In order to maintain the stability of pressure in the process,three control methods are proposed:inverse proportional control,fuzzy control and PID control.In addition,we use high strength steel as the workpiece and conduct three groups of machining efficiency comparative experiments.From these three groups of experiments,we conclude that the machining depth can reach to 14.5 mm and the force range is less than 1.0 Nby using PID control method.PID control method has advantages over the other two in machining efficiency and stability.
To improve the efficiency of electrical discharge machining(EDM)ablation,this paper uses a sintered diamond electrode as the machining electrode,making use of grinding action of diamond particles,to achieve machining combined with high efficiency ablation and mechanical grinding.In the study,through gathering mechanical grinding force during machining,a control method based on force signal is proposed to ensure diamond particles grinding.In order to maintain the stability of pressure in the process,three control methods are proposed:inverse proportional control,fuzzy control and PID control.In addition,we use high strength steel as the workpiece and conduct three groups of machining efficiency comparative experiments.From these three groups of experiments,we conclude that the machining depth can reach to 14.5 mm and the force range is less than 1.0 Nby using PID control method.PID control method has advantages over the other two in machining efficiency and stability.
引文
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[10]邱明波,凌加健,陈龙海,等.金刚石烧结电极放电烧蚀加工蚀除机理[J].机械工程学报,2015,51(3):190-195.QIU Mingbo,LING Jiajian,CHEN Longhai,et al.The mechanisms of processing by spark-induced combustion with sintered diamond electrode[J].Chinese Journal of Mechanical Engineering,2015,51(3):190-195.
[11]安庆龙.低温喷雾射流冷却技术及其在钛合金机械加工中的应用[D].南京:南京航空航天大学,2006.AN Qinglong.Cryogenic mist jet impingging cooling and its application in machining of titanium alloy[D].Nanjing:Nanjing University of Aeronautics and Astronautics,2016.
[12]CAO Z L,LIU Z D,LING J J,et al.Deep-type hole machining by inner jetted aerosol dielectric ablation[J].The International Journal of Advanced Manufacturing Technology,2015,78(9/10/11/12):1989-1998.
[13]赵万生.先进电火花加工技术[M].北京:国防工业出版社,2003:20-21.ZHAO Wansheng.Advanced EDM technology[M].Beijing:National Defence Industrial Press,2003:20-21.
[14]PEREIRA R D O,VERONESI M,VISIOLI A,et al.Implementation and test of a new auto-tuning method for PID controllers of TITO processes[J].Control Engineering Practice,2017,58:171-185.
[2]KUNIEDA M,YOSHIDA M,TANIGUCHI N.Electrical discharge machining in gas[J].CIRPAnnals,1997,46(1):143-146.
[3]李立青,王振龙,赵万生.气体放电加工机理分析[J].哈尔滨工业大学学报,2004,36(3):359-362.LI Liqing,WANG Zhenlong,ZHAO Wansheng.Mechanism analysis of electrical discharge machining in gas[J].Journal of Harbin Institute of Technology,2004,36(3):359-362.
[4]TANIMURA T,ISUZUGAWA K,FUJITA I,et al.Development of EDM in the mist[J].Proc.IJEM,1989(9):313-316.
[5]王祥志,刘志东,薛荣媛,等.极间自混氧改善钛合金电火花加工特性研究[J].航空学报,2013,34(10):2419-2426.WANG Xiangzhi,LIU Zhidong,XUE Rongyuan,et al.Research on self-mixed oxygen in discharge gap to improve the processing characteristics of titanium alloy electrical discharge machining[J].Acta Aeronautica et Astronautica Sinica,2013,34(10):2419-2426.
[6]刘志东.放电诱导可控烧蚀高效加工典型工艺方法[J].电加工与模具,2012(1):1-6.LIU Zhidong.Series typical efficient machining methods of controllable burning by discharge-induced[J].Electromachining and Mould,2012(1):1-6.
[7]耿春明,赵万生,赵家齐,等.电火花加工中间隙放电状态检测的一种新方法[J].电加工与模具,2001(3):27-29.GENG Chunming,ZHAO Wansheng,ZHAO Jiaqi,et al.A new method of testing spark states of the gap in EDM[J].Electromachining and Mould,2001(3):27-29.
[8]LIU Z D,CHEN H R,PAN H J,et al.Automatic control of WEDM servo for silicon processing using current pulse probability detection[J].The International Journal of Advanced Manufacturing Technology,2015,76(1/2/3/4):367-374.
[9]吴光河.基于模糊自适应PID的电火花成型加工伺服控制系统的研究[D].上海:上海海洋大学,2012.WU Guanghe.Research of EDM servo control system based on fuse control of PID[D].Shanghai:Shanghai Ocean University,2012.
[10]邱明波,凌加健,陈龙海,等.金刚石烧结电极放电烧蚀加工蚀除机理[J].机械工程学报,2015,51(3):190-195.QIU Mingbo,LING Jiajian,CHEN Longhai,et al.The mechanisms of processing by spark-induced combustion with sintered diamond electrode[J].Chinese Journal of Mechanical Engineering,2015,51(3):190-195.
[11]安庆龙.低温喷雾射流冷却技术及其在钛合金机械加工中的应用[D].南京:南京航空航天大学,2006.AN Qinglong.Cryogenic mist jet impingging cooling and its application in machining of titanium alloy[D].Nanjing:Nanjing University of Aeronautics and Astronautics,2016.
[12]CAO Z L,LIU Z D,LING J J,et al.Deep-type hole machining by inner jetted aerosol dielectric ablation[J].The International Journal of Advanced Manufacturing Technology,2015,78(9/10/11/12):1989-1998.
[13]赵万生.先进电火花加工技术[M].北京:国防工业出版社,2003:20-21.ZHAO Wansheng.Advanced EDM technology[M].Beijing:National Defence Industrial Press,2003:20-21.
[14]PEREIRA R D O,VERONESI M,VISIOLI A,et al.Implementation and test of a new auto-tuning method for PID controllers of TITO processes[J].Control Engineering Practice,2017,58:171-185.