CN104028861A - Electrical discharge machining level-by-level self-adaptive fuzzy control method of metal-ceramic functionally graded material - Google Patents
Electrical discharge machining level-by-level self-adaptive fuzzy control method of metal-ceramic functionally graded material Download PDFInfo
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Abstract
The invention provides an electrical discharge machining level-by-level self-adaptive fuzzy control method of a metal-ceramic functionally graded material, and belongs to the technical field of electrical discharge machining. The method aims to solve the problem that due to differences in components on all layers and structural characteristics of the metal-ceramic functionally graded material, through holes can hardly be machined in the metal-ceramic functionally graded material through the electrical sparks, and the problem that due to mismatching of energy inside the through holes, residual stress exists between different gradient layers, performance and the service life of parts made of the metal-ceramic functionally graded material are affected. By means of the structural characteristics of the material and the electrical discharge machining discharge state characteristics of the material, with changes of the electrical discharge machining discharge state on all layers of material of the functionally graded material serving as an excitation source, an electrical discharge machining fuzzy controller model of the metal-ceramic functionally graded material is established through combination with the fuzzy control theory, the real-time feedback control of the machining process is achieved, and energy matching is conducted level by level in a self-adaptive mode according to the differences of the machined material. The method is used for the machining control over the metal-ceramic functionally graded material.
Description
Technical field
The present invention relates to a kind of control strategy towards metal-ceramic FGM spark machined, belong to spark erosion technique field.
Background technology
Japanese scientist Xinye in 1987 just it, the quick hero of horizontal well and cross Bian Longsan and first proposed gradient distribution in conjunction with metal and this novel idea of super heat resistant ceramic, FGM becomes rapidly the study hotspot of material science subsequently, wherein the research of metal-ceramic FGM and demand are the most extensively with urgent, and its difficulty of processing is also very big.Metal-ceramic FGM is by metal and ceramic two phase compositions, and a side is pure pottery, and opposite side is simple metal, and between this, material component ratio and physical property through-thickness change in gradient.Due to the novelty of material itself and the diversity of requirement objective, the research of metal-ceramic FGM is mainly concentrated at present design and the preparation aspect of material both at home and abroad, to urgently research and development of the research of its processing method and process control technology thereof.
Spark machined is a kind of non-contact type process technology and without obvious macroscopical cutting force, it relies on the energetic plasma that between the two poles of the earth, dielectric breakdown forms to bombard surface of the work, make that skin-material melts, evaporation or hot soarfing from and realize the removal of material, so spark erosion technique has been widely used in high hardness material manufacture field.Especially in recent ten years, researcher has broken through the yoke of the tradition of thinking that for a long time spark machined can only processing electrically conductive material, adopts assisting electrode method, makes the spark machined of insulating properties material become possibility, and actively developed thus correlative study and test, obtained rapid progress.
Spark erosion technique is to utilize electrocaloric effect to realize the removal of material, carries out small hole drilling by EDM under the effect of constant machined parameters, if material composition evenly, can guarantee carrying out smoothly of aperture processing.Metal-ceramic FGM is that physical property and the mechanical property of heterogeneous material and different component material all exists larger difference, in functionally gradient material (FGM) spark machined aperture process, must occur that machining state is inconsistent like this, even identical machined parameters cannot adapt to the processing request of different gradient layers, cause metal-ceramic FGM to process smoothly, therefore need to carry out the research of spark machined adaptive control technology, namely need according to the different energy that carry out of the component of spark machined functionally gradient material (FGM) flux matched.
Spark machined control technology is the emphasis that domestic and international spark machined researcher pays close attention to always.High-resolution discharge condition detection technique and high-precision servo-control system are stable, the efficient important leverages of spark machined.Because metal-ceramic FGM is that the performance of two-phase multilayer materials and material metal layer, gradient layer and ceramic layer is different, so its special institutional framework has also determined the uniqueness of its spark machined control strategy.Processing method and process thereof for metal-ceramic FGM are controlled, and do not propose to utilize spark machined mode to realize the scheme of Adaptive Fuzzy Control step by step in prior art.
Summary of the invention
The object of this invention is to provide a kind of metal-ceramic FGM spark machined adaptive fuzzy control method step by step, to solve metal-ceramic FGM due to its each layer component and architectural characteristic difference, the difference of the flash-over characteristic of each layer occurring in the process of functionally gradient material (FGM) spark machined aperture and removal mechanism, in conventional process, be prone to the problem that cannot process through hole, and between different layers, adopt identical discharge parameter, because each layer of thermal conductivity factor difference makes to exist different residual stress to affect the problem in metal-ceramic Functional Gradient Materials serviceability and service life between the hole interior layer after processing.
The present invention solves the problems of the technologies described above the technical scheme of taking to be:
Metal-ceramic FGM spark machined is an adaptive fuzzy control method step by step, the multilayer complex functional functionally gradient material (FGM) that described metal-ceramic FGM is comprised of metal level, gradient layer and ceramic layer and to start to process ground floor material be conductive metal layer; Described control method utilizes fuzzy controller model to realize, and it is input quantity that fuzzy controller model be take short circuit ratio and spark rate, by expansion and velocity variable between arteries and veins, is output quantity, and the interval that is subordinate to of described input, output quantity is:
Short circuit ratio ∈ [0,1];
Spark rate ∈ [0,1];
Between arteries and veins, expand ∈ [0.5,4];
Velocity variable ∈ [2,2];
The process of utilizing described fuzzy controller model to carry out Adaptive Fuzzy Control to metal-ceramic FGM spark machined is: set initial machined parameters, start FGM to carry out spark machined, by discharge examination module, detect discharge voltage, the current parameters of electric discharge machining process simultaneously, and the discharge condition of discharge process is added up; Take short circuit ratio and spark rate as input quantity, by short circuit ratio membership function (as Fig. 2) and spark rate membership function (as Fig. 3), input quantity is carried out to Fuzzy processing; Utilize technological parameter storehouse to carry out reasoning as inference rule, by expansion and velocity variable between arteries and veins, it is output quantity, by expanding membership function (as Fig. 4) between arteries and veins and velocity variable membership function (as Fig. 5) carries out reverse gelatinization processing to output quantity, realize the real-time control to process.
Described metal-ceramic FGM spark machined discharge condition characteristic refers to: layers of material is stable adds discharge condition in man-hour different (can cause the stable man-hour discharge condition of adding of the sudden change of discharge condition and layers of material to have obvious difference when electric discharge processing proceeds to lower layer of material).
Described technological parameter storehouse is to utilize technological experiment to set up metal-ceramic FGM electrical discharge machining process database and as the sample of neutral net, enters optimum power parameter and the feed speed combination of the layers of material electric discharge processing that learning training obtains.
Metal-ceramic FGM spark machined fuzzy controller model is that to take short circuit ratio and the spark rate of electric discharge statistics of 2000 pulses in functionally gradient material (FGM) process be input quantity, take between arteries and veins expansion and velocity variable is output quantity, utilize technological parameter storehouse to carry out reasoning as inference rule, realize the real-time control to process.
The invention has the beneficial effects as follows:
Described method is carried out discharge condition to the feature of each layer of discharge condition of FGM spark machined and is detected and statistics, utilize the self structure characteristic of metal-ceramic FGM and spark machined discharge condition characteristic thereof and according to the variation of FGM layers of material spark machined discharge condition as excitaton source, in conjunction with fuzzy control theory, by short circuit ratio and spark rate, it is input quantity, pulsewidth expansion simultaneously and velocity variable are output quantity, realize the real-time feedback control of process, and it is flux matched according to the difference of Material Processing, to carry out adaptively step by step energy, until complete the processing of required size, described self adaptation comprises self adaptation between different machined layer and the self adaptation of identical layer different machining parameters.The real-time control of realization to process, the carrying out of the stability and high efficiency of assurance process, until machine.
The present invention is first for metal-ceramic FGM processing method and control technology thereof immature actual conditions still, for the application of expanded functionality functionally gradient material (FGM) has been carried out the research of metal-ceramic FGM spark machined control technology; Secondly in metal-ceramic FGM small hole drilling by EDM because the architectural characteristic of material own causes each layer of problem that discharge condition is inconsistent and difficulty of processing difference is large, fully study functionally gradient material (FGM) spark machined discharge condition feature, using the variation of functionally gradient material (FGM) different processing stages discharge condition as excitaton source and in conjunction with advanced fuzzy control technology, invent a kind of metal-ceramic FGM spark machined self-adjusted fuzzy control strategy (method) step by step.
Metal-ceramic FGM spark machined of the present invention step by step self-adjusted fuzzy control strategy provides assurance for efficiently, stably realizing the spark machined of metal-ceramic FGM; Utilize the exclusive feature combined with intelligent control technology of laminated gradient material spark machined discharge condition to complete the combination that building of control system promoted self-adapting intelligent control technology and industrial processes technology, enriched the intension of spark machined control technology simultaneously.
The present invention utilizes the variation of functionally gradient material (FGM) different processing stages discharge condition, as excitaton source, metal-ceramic FGM edm process is carried out to real-time feedback control, can according to the adaptive adjustment power parameter of the difference of Material Processing, realize the Auto-matching of machining energy, overcome and utilized identical energy to carry out the unstable and unmanageable problem of ceramic layer of discharge condition that spark machined causes due to the ablation mechanism difference of material to different materials.The present invention utilizes neutral net to be optimized metal-ceramic FGM electrical discharge machining process database, can further improve the validity of proposed control strategy.
The inventive method is a kind of graded of utilizing material metal base and ceramic base content specifically, the discharge condition of functionally gradient material (FGM) different processing stages of usining changes carries out real-time feedback control as excitaton source, realizes a kind of spark machined ADAPTIVE CONTROL that composite different component spark machined can be flux matched.The present invention is directed to metal-ceramic FGM because its each layer component and architectural characteristic are different, cause in process each layer of spark discharge to the ablation mechanism difference of material and the larger characteristic of discharge condition difference; The discharge condition of research spark machined metal-ceramic FGM layers of material, using the variation of functionally gradient material (FGM) different processing stages discharge condition as excitaton source and in conjunction with advanced intelligent control technology, and invention metal-ceramic FGM spark machined is self-adjusted fuzzy control strategy step by step.The research that launches spark machined control technology for metal-ceramic FGM is one and has novelty and challenging research work, its achievement in research not only can be enriched the intension of spark machined, and significant to processing and the application level of lifting China advanced composite material.
Accompanying drawing explanation
Fig. 1 is Adaptive Fuzzy Control flow chart of the present invention; Fig. 2 is short circuit ratio membership function figure; Fig. 3 is spark rate membership function figure; Fig. 4 expands membership function figure between arteries and veins; Fig. 5 is velocity variable membership function figure; Fig. 6 processes Ni-Al under different control systems
2o
3fGM discharge waveform comparison diagram, wherein: a is conventional controlled working oscillogram, b is the processing of Adaptive Fuzzy Control step by step oscillogram; Fig. 7 is that self-adjusted fuzzy control strategy and conventional control strategy contrast picture (in figure: 1-adopts self-adjusted fuzzy control strategy machining hole, 2-to adopt conventional control method machining hole, 3-metal level, 4-ceramic layer) to the experiment of cermet FGM hole processing.
The specific embodiment
A kind of metal-ceramic FGM spark machined is adaptive fuzzy control method step by step, embodied fully the combination between material structure characteristic and electric discharge machining method, below in conjunction with accompanying drawing, the specific embodiment of the invention has been further described.
The specific embodiment one:
Metal-ceramic FGM spark machined is an adaptive fuzzy control method step by step, the multilayer complex functional functionally gradient material (FGM) that described metal-ceramic FGM is comprised of metal level, gradient layer and ceramic layer and to start to process ground floor material be conductive metal layer; Described control method utilizes fuzzy controller model to realize, and it is input quantity that fuzzy controller model be take short circuit ratio and spark rate, by expansion and velocity variable between arteries and veins, is output quantity, and the interval that is subordinate to of described input, output quantity is:
Short circuit ratio ∈ [0,1];
Spark rate ∈ [0,1];
Between arteries and veins, expand ∈ [0.5,4];
Velocity variable ∈ [2,2];
The process of utilizing described fuzzy controller model to carry out Adaptive Fuzzy Control to metal-ceramic FGM spark machined is: set initial machined parameters, start FGM to carry out spark machined, by discharge examination module, detect discharge voltage, the current parameters of electric discharge machining process simultaneously, and the discharge condition of discharge process is added up; Take short circuit ratio and spark rate as input quantity, by short circuit ratio membership function (as Fig. 2) and spark rate membership function (as Fig. 3), input quantity is carried out to Fuzzy processing; Utilize technological parameter storehouse to carry out reasoning as inference rule, by expansion and velocity variable between arteries and veins, it is output quantity, by expanding membership function (as Fig. 4) between arteries and veins and velocity variable membership function (as Fig. 5) carries out reverse gelatinization processing to output quantity, realize the real-time control to process.Described metal-ceramic FGM spark machined discharge condition characteristic refers to: layers of material is stable adds discharge condition in man-hour different (can cause the stable man-hour discharge condition of adding of the sudden change of discharge condition and layers of material to have obvious difference when electric discharge processing proceeds to lower layer of material).Described technological parameter storehouse is to utilize technological experiment to set up metal-ceramic FGM electrical discharge machining process database and as the sample of neutral net, enters optimum power parameter and the feed speed combination of the layers of material electric discharge processing that learning training obtains.Described metal-ceramic FGM spark machined fuzzy controller model is that to take short circuit ratio and the spark rate of electric discharge statistics of 2000 pulses in functionally gradient material (FGM) process be input quantity, take between arteries and veins expansion and velocity variable is output quantity, utilize technological parameter storehouse to carry out reasoning as inference rule, realize the real-time control to process.
Tool-electrode and workpiece are distinguished to clamping to electric spark experiment porch, and workpiece is immersed in kerosene, opens procedure.Metal-ceramic FGM produces rapidly Spark Discharges with tool-electrode under the effect of power pulse.Utilize discharge examination module, the voltage in electric discharge machining process, electric current are detected and gathered.Utilize electric discharge statistical module to add up 2000 corresponding short circuit and spark discharges of power pulse.Statistics short circuit ratio and spark rate are input to fuzzy controller and carry out Fuzzy processing, according to technological parameter storehouse, carry out reasoning, result after reasoning is carried out to reverse gelatinization processing output, between existing processing arteries and veins and feed speed parameter change the processing of the stability and high efficiency of realizing spark machined metal-ceramic FGM processing.Then whether judgement processing completes, if do not completed, continues to carry out above-mentioned adaptive control process, finally realize process step by step Adaptive Fuzzy Control until complete the processing of required size.
The specific embodiment two
What this enforcement was different from enforcement one is that the described pulse power is the controlled RC pulse power of transistor, and other step is identical with the specific embodiment one.
Fig. 7 shows and adopts adaptive fuzzy control strategy and the conventional control method processing contrast to metal-ceramic FGM step by step: conventional control method is fixed because of machined parameters in machining hole process, when being worked into pottery layer, cannot form stable conducting film, so cannot process through hole smoothly on metal-ceramic FGM.Adopt adaptive fuzzy control strategy step by step to carry out parameter optimum combination according to the characteristic of different material layer, when being worked into gradient layer that ceramic component content is high and ceramic layer, can form stable conducting film by controlling electrical quantity, realize and process through hole on metal-ceramic FGM.
Adopt conventional some spark control strategy, because being worked into after ceramic layer, discharge electrode is unstable, is difficult to the formation of conducting film in controlled working process, causes the ceramic layer cannot normal process.Adopt the formation that can effectively keep conducting film after self-adjusted fuzzy control strategy, processing can be carried out smoothly, complete the smooth processing of metal-ceramic FGM.
The above; it is only the preferably specific embodiment of the present invention; but protection scope of the present invention is not limited to this; anyly be familiar with those skilled in the art in the technical scope that the present invention discloses; according to technical scheme of the present invention and inventive concept thereof, be equal to replacement or changed, within all should being encompassed in protection scope of the present invention.
The work base reason of the inventive method:
Discharge condition and its material component of described metal-ceramic FGM spark machined have close relationship, the electric spark ablation of metal level is to rely on the energy that spark discharge produces in workpiece side to melt, gasify and utilize instantaneous temperature to raise the material ablation of fusing or gasification in metal material, has voltage and the current waveform of typical spark discharge processing; Gradient layer is because being mixed with ceramic particle in material, and fusing point and the boiling point of pottery will be far above fusing point and the boiling points of metal, when utilizing spark machined gradient layer, the ablation mode of material is mainly to rely on after ceramic particle metal ablation around, coming off because lacking to support of ceramic particle, and follow a small amount of ceramic particle fusing and gasification phenomenon, to reach the object of rapidoprint; The most unmanageable ceramic layer as metal-ceramic function-graded material, by spark machined, just need to set up conductive phase, in process, the foundation of conductive phase is by the carbon that disintegration liquid produces in processing gradient layer process, to be deposited on ceramic surface to form, by the energy ablation pottery of the discharge generation between instrument and carbon film, in the process of this layer, the obvious increase of Light Condition and electric current and voltage are compared and are had obvious difference with metal level and gradient layer processing.Utilize discharge voltage that the difference of ablation mechanism between each layer produces and electric current and no-load characteristic as the excitaton source of this fuzzy control, the signals such as electric current and voltage in process are monitored in real time, and technological parameter is carried out to implementation modification, reached the metal-ceramic material effect of adaptive machining step by step.
The gradient layer of described metal-ceramic FGM is to one deck of ceramic layer transition, to have the composite that electric conductivity changes along gradient direction by metal level.
Described metal-ceramic FGM spark machined discharge condition feature is embodied in and because the insulating ceramics content of material own is higher, causes on the one hand that process is extremely unstable and Light Condition is more; On the other hand because material is multiple layered structure, when proceeding to gradient layer or lower layer of material, electric discharge processing can cause the stable man-hour discharge condition of adding of the sudden change of discharge condition and layers of material also can have obvious difference.
It is the discharge condition detection technique of carrying out in order accurately to distinguish process short-circuit condition and spark discharge state for metal-ceramic FGM spark machined discharge condition feature that described discharge condition detects, its principle is benchmark for utilizing a threshold voltage, short circuit and spark discharge voltage signal are converted into the square-wave signal relevant with discharge time and distinguish, with regard to having solved because both average voltages are more or less the same, cause the problem of utilizing average electrical platen press to be difficult to them accurately to distinguish like this.
Described discharge condition statistics is based on above-mentioned discharge condition detection technique, the discharge condition statistical method that the pulse number of take is a measurement period as unit, every 2000 pulses.
Described fuzzy controller is to using short circuit ratio in process and spark rate as input quantity, usings between arteries and veins expansion and feed speed variable quantity as output quantity.Membership function (Fig. 3) by input quantity short circuit ratio membership function (Fig. 2) and spark rate carries out Fuzzy processing, utilize technological parameter storehouse to carry out reasoning as inference rule, decision-making output fuzzy quantity, and by the reasoning results according to expanding membership function (Fig. 4) between arteries and veins and velocity variable membership function (Fig. 5) carries out reverse gelatinization processing, using between arteries and veins, propagation and feed speed variable quantity, as output quantity, are realized efficient, the stable processing to metal-ceramic FGM.
Described technological parameter storehouse is to utilize technological experiment to set up metal-ceramic FGM electrical discharge machining process database and as the sample of neutral net, enters optimum power parameter and the feed speed combination of the layers of material electric discharge processing that learning training obtains.
Therefore in whole process, tool-electrode can be realized within the scope of rotating speed 0-4000r/min adjustablely under the drive of high-speed main spindle, not only can realize dark aperture spark machined but also can complete Electric Discharge Machining.
Embodiment:
Workpiece is connected with positive source, and tool-electrode is connected with the negative pole of power supply, and workpiece, tool-electrode and power supply form discharge loop in process.Under identical initial manufacture condition, adopt respectively powder mixed dielectric EDM control method and step by step adaptive fuzzy control method process contrast test.From Fig. 6 discharge waveform, figure can clearly be seen that, powder mixed dielectric EDM control system is at Ni-Al
2o
3in FGM processing, only rely on simple average electrical platen press to carry out SERVO CONTROL, in processing waveform, there will be a large amount of improper discharge waveforms (as shown in Figure 6 a), improper discharge condition will directly affect stability and the working (machining) efficiency of spark machined.Adopt Adaptive Fuzzy Control step by step will improve the improper discharge condition (as shown in Figure 6 b) in process, processing as can be seen from Figure waveform is all that material is removed to useful spark discharge waveform substantially, this be because if in process if there is a large amount of improper discharge condition shown in Fig. 6 a, first the Fuzzy control system of this programme will be controlled power supply, adopt between the expansion arteries and veins abundant deionization of chien shih machining area or compression arteries and veins and improve working (machining) efficiency and reduce no-load ratio, if now machining state does not still effectively improve, carrying out feed speed controls, be used for improving machining area galvanic corrosion product and discharge effect, and then complete the control to processing stability, and original system of processing just utilizes the mean value of machining voltage and reference servo magnitude of voltage to compare, then servo-drive system is carried out accordingly and is moved machining state is improved.Fig. 7 has shown that two kinds of control methods are to Ni-Al
2o
3the final result of FGM spark machined through hole, result shows: adopt the conventional electric spark control method cannot be at Ni-Al
2o
3on FGM, process through hole, adopt the adaptive fuzzy control method step by step, can be at Ni-Al because having improved the stability of process spark discharge
2o
3on FGM, process through hole.
Claims (4)
1. a metal-ceramic FGM spark machined adaptive fuzzy control method step by step, the multilayer complex functional functionally gradient material (FGM) that described metal-ceramic FGM is comprised of metal level, gradient layer and ceramic layer and to start to process ground floor material be conductive metal layer; It is characterized in that: described control method utilizes fuzzy controller model to realize, it is input quantity that fuzzy controller model be take short circuit ratio and spark rate, by expansion and velocity variable between arteries and veins, is output quantity, and the interval that is subordinate to of described input, output quantity is:
Short circuit ratio ∈ [0,1];
Spark rate ∈ [0,1];
Between arteries and veins, expand ∈ [0.5,4];
Velocity variable ∈ [2,2];
The process of utilizing described fuzzy controller model to carry out Adaptive Fuzzy Control to metal-ceramic FGM spark machined is: set initial machined parameters, start FGM to carry out spark machined, by discharge examination module, detect discharge voltage, the current parameters of electric discharge machining process simultaneously, and the discharge condition of discharge process is added up; Take short circuit ratio and spark rate as input quantity, by short circuit ratio membership function and spark rate membership function, input quantity is carried out to Fuzzy processing; Utilizing technological parameter storehouse to carry out reasoning as inference rule, is output quantity by expansion and velocity variable between arteries and veins, by expanding membership function and velocity variable membership function between arteries and veins, output quantity is carried out to reverse gelatinization processing, realizes the real-time control to process.
2. a kind of metal-ceramic FGM spark machined according to claim 1 adaptive fuzzy control method step by step, it is characterized in that, described metal-ceramic FGM spark machined discharge condition characteristic refers to the stable discharge condition difference in man-hour that adds of layers of material.
3. a kind of metal-ceramic FGM spark machined according to claim 2 adaptive fuzzy control method step by step, it is characterized in that, described technological parameter storehouse is to utilize technological experiment to set up metal-ceramic FGM electrical discharge machining process database and as the sample of neutral net, optimum power parameter and the feed speed combination of the layers of material electric discharge processing obtaining through learning training.
4. according to the adaptive fuzzy control method step by step of a kind of metal-ceramic FGM spark machined described in claim 1,2 or 3, it is characterized in that, metal-ceramic FGM spark machined fuzzy controller model is that to take short circuit ratio and the spark rate of electric discharge statistics of 2000 pulses in functionally gradient material (FGM) process be input quantity, take between arteries and veins expansion and velocity variable is output quantity, utilize technological parameter storehouse to carry out reasoning as inference rule, realize the real-time control to process.
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| CN110293270A (en) * | 2019-07-02 | 2019-10-01 | 哈尔滨工业大学 | Insulative ceramic coatings-metal material electrical discharge machining material type device for identifying and method |
| CN110142470B (en) * | 2019-07-02 | 2020-06-19 | 哈尔滨工业大学 | Parameter self-adjusting pulse power supply for insulating ceramic coating-metal electric spark machining |
| CN110293270B (en) * | 2019-07-02 | 2020-07-17 | 哈尔滨工业大学 | Material type identification device and method for electric spark machining of insulating ceramic coating-metal material |
| CN114462274A (en) * | 2022-01-21 | 2022-05-10 | 哈尔滨工业大学 | Design method of functional gradient piezoelectric composite material integrator |
| CN114462274B (en) * | 2022-01-21 | 2024-10-11 | 哈尔滨工业大学 | Design method of functionally gradient piezoelectric composite material integrator |
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