基于超声调制静电驱动的微细电火花加工新方法研究

At present, bottlenecks still exist on micro discharge machining(micro EDM),such as low-precision of servo feed, debris removal difficulty and poor processing stability, these problems restrict manufacturing of micro parts. Besides, the micro EDM technology and theory research have certain limitations in the past. With regard to the current situation, this project which focus on the micro EDM machine tool, first proposes the micro EDM method that based on ultrasonic modulation electrostatic driven, applies the new theory of electrostatically actuated micro feed, builds the adaptive discharge mechanism of ultrasonic vibration modulated electrostatic driven micro feeding and pulse power, and establishes its discharge channel model and material removal model. In addition, the project analyzes the process law of micro EDM based on ultrasonic modulation electrostatic driven through a lot of experiment, and reveals it's new mechanism. The project plays a catalytic role on the study of the mechanism of micro EDM, and provides a theoretical basis and technical support for the development of micro EDM.

本项目以微细电火花机床为研究对象，首次提出了超声调制静电驱动的微细电火花加工方法，应用静电驱动微进给的新理论，建立超声振动调制静电驱动微进给和脉冲电源自适应放电实现机制，研究并建立其放电通道模型和材料去除模型，通过大量工艺试验来分析超声调制静电驱动微细电火花加工规律，揭示超声调制静电驱动的微细电火花加工新机理。该项目对微细电火花加工机理研究起推动作用，为微细电火花机床研制提供理论依据和技术支持。

针对目前微细电火花加工伺服驱动进给精度不高、排屑困难、加工稳定性差等长期制约微小零件制造的瓶颈问题，以及目前微细电火花加工技术和理论研究的局限性，本项目以微细电火花机床为研究对象，提出了静电驱动的微细电火花加工方法进行研究， 并进一步拓展研究基于静电驱动的微细电解电火花复合加工方法。实验结果表明，该方法实现了伺服精微进给，更精确的控制放电间隙，提高了加工精度、加工质量和稳定性，满足小型化和精密化产品的要求，具有重要的理论意义和工程应用价值。