CN103909314B - High speed to-and-fro thread feed electric spark linear cutter working solution life-span online method for rapidly judging - Google Patents
High speed to-and-fro thread feed electric spark linear cutter working solution life-span online method for rapidly judging Download PDFInfo
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- CN103909314B CN103909314B CN201410118357.XA CN201410118357A CN103909314B CN 103909314 B CN103909314 B CN 103909314B CN 201410118357 A CN201410118357 A CN 201410118357A CN 103909314 B CN103909314 B CN 103909314B
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- 239000012224 working solution Substances 0.000 title claims abstract description 56
- 238000000034 method Methods 0.000 title claims abstract description 21
- 238000010892 electric spark Methods 0.000 title claims abstract description 10
- 238000005070 sampling Methods 0.000 claims abstract description 18
- 238000005520 cutting process Methods 0.000 claims abstract description 16
- JEIPFZHSYJVQDO-UHFFFAOYSA-N ferric oxide Chemical compound O=[Fe]O[Fe]=O JEIPFZHSYJVQDO-UHFFFAOYSA-N 0.000 claims abstract description 8
- 239000007788 liquid Substances 0.000 claims description 9
- 239000000839 emulsion Substances 0.000 claims description 6
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 6
- 230000015572 biosynthetic process Effects 0.000 claims description 5
- 238000003786 synthesis reaction Methods 0.000 claims description 5
- 150000001875 compounds Chemical class 0.000 claims description 4
- 238000012545 processing Methods 0.000 description 8
- 238000003754 machining Methods 0.000 description 7
- 230000008859 change Effects 0.000 description 6
- 230000008569 process Effects 0.000 description 5
- 238000005516 engineering process Methods 0.000 description 3
- 239000002131 composite material Substances 0.000 description 2
- 239000000110 cooling liquid Substances 0.000 description 2
- 238000001514 detection method Methods 0.000 description 2
- 238000010586 diagram Methods 0.000 description 2
- 230000004069 differentiation Effects 0.000 description 2
- 239000000203 mixture Substances 0.000 description 2
- 230000009467 reduction Effects 0.000 description 2
- 238000011160 research Methods 0.000 description 2
- 238000009763 wire-cut EDM Methods 0.000 description 2
- 230000009286 beneficial effect Effects 0.000 description 1
- 238000005553 drilling Methods 0.000 description 1
- 238000009760 electrical discharge machining Methods 0.000 description 1
- 239000003792 electrolyte Substances 0.000 description 1
- 230000001804 emulsifying effect Effects 0.000 description 1
- 238000002474 experimental method Methods 0.000 description 1
- 239000003350 kerosene Substances 0.000 description 1
- 239000000463 material Substances 0.000 description 1
- 230000007246 mechanism Effects 0.000 description 1
- 239000007769 metal material Substances 0.000 description 1
- 238000012360 testing method Methods 0.000 description 1
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- Electrical Discharge Machining, Electrochemical Machining, And Combined Machining (AREA)
Abstract
A kind of high speed to-and-fro thread feed electric spark linear cutter working solution life-span online method for rapidly judging, is characterized in that: first, by no-load current umber of pulse in one sampling period of sample circuit taken at regular intervals or (short circuit+electric discharge) amount of current pulses；Secondly, calculate no-load current umber of pulse or (short circuit+electric discharge) amount of current pulses accounts for the ratio of the pulse in the sampling period: the 3rd, it is handled as follows according to gained ratio: if bar pulse ratio≤10% or (short circuit+electric discharge) impulse ratio are more than >=70%, then it represents that working solution is working properly；If bar pulse ratio between 10%～20% or (short circuit+electric discharge) impulse ratio between 60%～70%, then it represents that cutting can be made to be normally carried out by adjusting cutting parameter；If bar pulse ratio ＞ 20% or (short circuit+electric discharge) impulse ratio ＜ 60%, representing that working solution lost efficacy need to be replaced.The present invention is simple, and real-time is good, and accuracy rate is high.
Description
Technical field
The present invention relates to a kind of spark cutting process technology, especially a kind of Wire-cut Electrical Discharge Machining electrolyte duty discrimination technology, specifically a kind of high speed to-and-fro thread feed electric spark linear cutter working solution life-span online method for rapidly judging.
Background technology
At present, the cutting of high speed to-and-fro thread feed electric spark line is spark erosion technique with Chinese characteristics, and the use of its discharge medium experienced by from kerosene, common emulsion, the line cutting different developmental stage such as special-purpose emulsifying liquid and synthetic work liquid.At present, the working solution that domestic market commonly uses can be divided into three kinds, i.e. oil base emulsion, water base synthesis liquid and composite cooling liquid.The characteristic of working solution directly influences the technic indexs such as the stability of cutting speed, machined surface quality, thickness of processing piece, machining accuracy and processing.And the performance of working solution is relevant with its composition, concentration and degree of fouling etc..Under current processing conditions, the change of working solution in use its performance is uncontrollable, and the judgement causing cut state is relied primarily on experience and carries out by such result.Therefore the characteristic index that job search liquid lost efficacy, in order to monitor working solution state in time, it has also become urgent problem, and this is also the needs that high-speed wire electrical discharge machine tool develops to further controlledization.
Aborning, experienced operator are the experiences according to oneself or are reduced by efficiency and judge whether working solution lost efficacy, and this method operability is the lowest.Also there are some research worker, from of the working solution itself, have studied the electrical conductivity of working solution, concentration, pH value and viscosity etc., in order to find out working solution and lost efficacy relevant with which factor, thus want to judge whether working solution lost efficacy by more scientific method.Research through related personnel finds that concentration, pH value and viscosity use along with the long-time of working solution, and its changing value is less, it is impossible in order to as the index judging that working solution lost efficacy.Although by the change of composite cooling liquid electrical conductivity, people may determine that whether working solution lost efficacy, but working solution composition on the market is different, and various places water quality is different, kind is different, and concentration is the most different, and the electrical conductivity of the most different working solutions is also different.So being used as checking working solution whether to lose efficacy by electrical conductivity, its versatility is bad, so being not to be used as detecting the maximally effective way that working solution lost efficacy.
Summary of the invention
It is an object of the invention to rely primarily on for the differentiation of current working solution manually differentiate according to concentration, pH value and viscosity, cause that judgment accuracy is poor, have time delay, often actively to differentiate at the cutting member quality Shi Caihui that goes wrong, can not realize reflecting the problem such as cutting processing state, invent a kind of working solution state and can automatic alarm or the high speed to-and-fro thread feed electric spark linear cutter working solution life-span online method for rapidly judging of prompting of reflecting in real time.
The technical scheme is that
A kind of high speed to-and-fro thread feed electric spark linear cutter working solution life-span online method for rapidly judging, is characterized in that it comprises the following steps:
First, by no-load current umber of pulse in one sampling period of sample circuit taken at regular intervals or (short circuit+electric discharge) amount of current pulses；
Secondly, calculate no-load current umber of pulse or (short circuit+electric discharge) amount of current pulses account for the ratio of the pulse in the sampling period:
3rd, it is handled as follows according to gained ratio:
If bar pulse ratio≤10% or (short circuit+electric discharge) impulse ratio are more than >=70%, then it represents that working solution is working properly；
If bar pulse ratio between 10%～20% or (short circuit+electric discharge) impulse ratio between 60%～70%, then it represents that cutting can be made to be normally carried out by adjusting cutting parameter；
If bar pulse ratio ＞ 20% or (short circuit+electric discharge) impulse ratio ＜ 60%, representing that working solution lost efficacy need to be replaced.
When bar pulse ratio between 10%～20% or (short circuit+electric discharge) impulse ratio between 60%～70% time the automatic display reminding of system.
When bar pulse ratio ＞ 20% or (short circuit+electric discharge) impulse ratio ＜ 60% then system automatic alarm prompting.
Described working solution is oil type emulsion, water base synthesis liquid and compound working solution.
Beneficial effects of the present invention:
Applicant finds through great many of experiments, and during line cutting normal process, the probability of effective current electric discharge is more than 80%, and unloaded and short circuit probability is about 5-10%.What therefore the reduction in working solution life-span embodied is exactly the efficiency reduction of cutting, and namely pulse utilization rate reduces.
The inventive method is simple and easy to do; and it is to judge the failure behaviour of working solution from discharge mechanism angle; very science; and only need to increase a current impulse sample circuit in original control circuit plus simply comparing calculation procedure; i.e. can determine whether whether working solution lost efficacy; the automatization level of linear cutter can be increased substantially, the most do not shut down replacing working solution for next step and lay a good foundation.
The present invention is applied widely, and the working solution used in existing spark machined is suitable for by its principle.
The present invention is conducive to improving process velocity and crudy, reduces the generation of the machining failures such as fracture of wire, can extend time between failures, extends the service life of wire electrode.
Accompanying drawing explanation
Fig. 1 is three kinds of discharge condition schematic diagrams of existing metal material spark machined.
The bar pulse overhaul flow chart of Fig. 2 present invention.
The structured flowchart schematic diagram of zero load (short circuit+electric discharge) current sampling system of Fig. 3 present invention.
Fig. 4 represents pulse probabilities detection waveform figure before and after working solution inefficacy.Wherein: Fig. 4 a processes initial period waveform, pulse utilization rate > 90%；Fig. 4 b working solution inefficacy period waveform, pulse utilization rate is about 50%.
Detailed description of the invention
The present invention is further illustrated with embodiment below in conjunction with the accompanying drawings.
As Figure 1-4.
A kind of high speed to-and-fro thread feed electric spark linear cutter working solution life-span online method for rapidly judging, it comprises the following steps:
First, by sample circuit (such as Fig. 3) periodically (can sets itself, as interval 1 minute, 3 minutes, 5 minutes, 10 minutes or more than) gather no-load current umber of pulse or (short circuit+electric discharge) amount of current pulses in a sampling period；
Secondly, calculate no-load current umber of pulse or (short circuit+electric discharge) amount of current pulses account for the ratio of the pulse in the sampling period:
3rd, it is handled as follows according to gained ratio:
If bar pulse ratio≤10% or (short circuit+electric discharge) impulse ratio are more than >=70%, then it represents that working solution is working properly；
If bar pulse ratio between 10%～20% or (short circuit+electric discharge) impulse ratio between 60%～70%, then it represents that cutting can be made to be normally carried out by adjusting cutting parameter, system is automatically reminded to operator and carries out parameter adjustment；The system entrance next sampling period carries out sample count differentiation again；
If bar pulse ratio ＞ 20% or (short circuit+electric discharge) impulse ratio ＜ 60%, representing that working solution lost efficacy need to be replaced, and system is automatically reminded to operator and changes working solution.
System repeats above procedure automatically, until process finishing, as shown in Figure 2.
The working solution of the present invention can be oil type emulsion, water base synthesis liquid or compound working solution.
The operation principle of the present invention is:
The present invention is with pulsed current signal as sampled signal, within the sampling period, unloaded or short circuit+electric discharge current impulse probability of occurrence is acquired obtaining the current impulse probability of zero load or short circuit+electric discharge by sample circuit, and with numeral method out, thus can facilitate, know its machining state intuitively, as shown in Figure 1；The number that unloaded or short circuit+electric discharge current impulse probability of sampling refers to produce the pulse of the electric current of zero load or short circuit+electric discharge accounts for the percentage ratio of sampling period overall pulse number；Unloaded to sampling or short circuit+electric discharge the current impulse probability of microprocessor is used to calculate, store and show, unloaded for sampling or short circuit+electric discharge current impulse probability is compared with set probability, the machining state shown according to it, the electrical quantity of regulation lathe so that it is maintain optimal cut state.When, within a period of time, when the ratio that unloaded or short circuit+electric discharge current impulse probability accounts for overall pulse reaches a certain setting ratio, instrument will send cue, then be further determined whether to need to change working solution by operator.
Understanding according to Wire-cut Electrical Discharge Machining test, in the case of discharged condition is preferable, regular picture impulse ratio is generally about 80%, and bar pulse ratio is about 10%, and short circuit pulse ratio is about 10%.Because current impulse all can be produced in normal process pulse and short circuit pulse, so in the case of discharged condition is preferable, it is about 90% that the current impulse of short circuit+electric discharge produces probability.Owing to processing mode (Wire EDM, edm forming, electric-spark drilling etc.), object and condition are different, preferably the current impulse probability of short circuit+electric discharge also can change within the specific limits, generally 70%-90%.So set unloaded probability when working solution lost efficacy be generally 10% 20% or the current impulse probability of short circuit+electric discharge typically proper between 60%-70%, when detecting that the unloaded probability current impulse probability between 10% 20% or short circuit+electric discharge will send cue between 60%-70%, system.Such as Fig. 4, set the current impulse probability of short circuit+electric discharge less than 60%, use new working solution, and according to the probability regulation machined parameters of display, make it maintain optimal machining state workpiece material is processed, current impulse probability in initial period short circuit+electric discharge is more than 90% as can be seen from Figure 4, after processing a period of time, when the probability of detection is less than 70%, system will send cue, operator are reminded to regulate machined parameters, it is made to maintain normal machining state, when the current impulse probability of display short circuit+electric discharge is in 50% fluctuation, less than 60% set, and regulation machined parameters can not change its machining state, now should change working solution.
The working solution life-span tester of the present invention is applicable to current all working liquid, can be used for oil type emulsion, water base synthesis liquid or compound working solution etc. as the criterion lost efficacy.Sample circuit shown in Fig. 3 is with pulse current probability for servo foundation, and microprocessor accepts the signal of sample circuit, thus calculates the current impulse probability of the zero load in the sampling period or short circuit+electric discharge；Current impulse probability and the current impulse probability of set zero load or short circuit+electric discharge according to the zero load in the sampling period or short circuit+electric discharge compare to judge whether working solution lost efficacy.Sampling period can be changed according to the object of processing and processing request.
Part that the present invention does not relate to is the most same as the prior art maybe can use prior art to be realized.
Claims (2)
1. a high speed to-and-fro thread feed electric spark linear cutter working solution life-span online method for rapidly judging, is characterized in that it comprises the following steps:
First, by no-load current umber of pulse in one sampling period of sample circuit taken at regular intervals or (short circuit+electric discharge) amount of current pulses；
Secondly, calculate no-load current umber of pulse or (short circuit+electric discharge) amount of current pulses account for the ratio of the pulse in the sampling period:
3rd, it is handled as follows according to gained ratio:
If bar pulse ratio≤10% or (short circuit+electric discharge) impulse ratio are more than >=70%, then it represents that working solution is working properly；
If bar pulse ratio between 10%～20% or (short circuit+electric discharge) impulse ratio between 60%～70%, then it represents that cutting can be made to be normally carried out and by the automatic display reminding of system by adjusting cutting parameter；
If bar pulse ratio ＞ 20% or (short circuit+electric discharge) impulse ratio ＜ 60%, representing that working solution lost efficacy need to be replaced；
Described working solution is oil type emulsion, water base synthesis liquid and compound working solution.
Method the most according to claim 1, is characterized in that when bar pulse ratio > 20% or the prompting of (short circuit+electric discharge) impulse ratio ＜ 60% then system automatic alarm.
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| CN109158717A (en) * | 2018-10-24 | 2019-01-08 | 江苏德瑞加数控机床有限公司 | Spark discharge gap automatic control system based on self learning neural networks |
| CN113770462B (en) * | 2021-08-03 | 2023-10-31 | 华锠永晟智能科技(昆山)有限公司 | Wire feeding equipment for wire electric discharge machine |
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| JPH1015737A (en) * | 1996-07-03 | 1998-01-20 | Sodick Co Ltd | Method and device for testing quality of working fluid for electric discharge machining |
| JP3662677B2 (en) * | 1996-07-15 | 2005-06-22 | 三菱電機株式会社 | Wire electric discharge machine and wire electric discharge machining method |
| EP2018923B1 (en) * | 2000-12-25 | 2013-11-20 | Fanuc Corporation | Controller for wire electric discharge machine |
| JP2005066738A (en) * | 2003-08-22 | 2005-03-17 | Fanuc Ltd | Machining control method for wire-cut electric discharge machine |
| CN102909447B (en) * | 2012-09-19 | 2014-06-18 | 南京航空航天大学 | Electric spark servo control method based on current pulse probability detection |
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