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摘要: 電火花線切割加工(wire-EDM)是一種基于電火花加工技術的適應性流程加工技術,它可以被用在具有二維到三維復雜形狀的而且是導電的原材料的加工上。電火花線切割加工最常見的應用是在壓模、擠壓模、粉末冶金的鑄模和標準摸板的裝配工中。這樣就可以加工出以往依靠花費很高磨床或昂貴的傳統(tǒng)意義上的電火花的電極來進行加工的工件。由于電火花線切割加工技術是機電一體化技術,是機械、電工、電子、數(shù)控、自動控制、計算機應用等多門學科、專業(yè)知識的綜合運用。
我的設計課題是DK7732數(shù)控高速走絲電火花線切割機及控制系統(tǒng)設計。DK為數(shù)控電加工機床,77為電火花線切割機床,32為機床工作臺寬度。
此次設計包括機床的總體布局設計,橫向進給、縱向進給設計,其中還包括齒輪的強度計算,滾珠絲桿較核,軸承壽命的驗算。控制系統(tǒng)部分包括步進電機控制電路和脈沖電源電路,這是數(shù)控電火花加工機床的重點設計部分,也是難點。步進電機電路設計包括硬件電路設計和軟件系統(tǒng)設計。詳細說明了芯片的擴展、鍵盤顯示器接口的設計等等。脈沖電源電路采用高低壓復式脈沖電源,它是由晶體管及分立元件組成的電路,輸出高低壓復式脈沖,可以同時供給兩個放電間隙加工,提高生產(chǎn)效率。
關鍵字:數(shù)控高速電火花線切割加工、主軸運動、步進電機、脈沖電源。
Abstract: Wire electrical-discharge machining(wire-EDM) is an adaptation of the basic EDM process, which can be use for cutting complex two-and-three-dimensional shapes through electrically conducting materials. Wire-EDM is most commonly used for the fabrication of press stamping dies, extrusion dies, powder composition dies, profile gages, and templates. Complicated cutouts can be made in difficult-to-machine metals without the need for high-cost grinding or expensive shaped EDM electrodes, Because the technology of wire electrical-discharge machining is the technology of mechatronics, and it is the integrate application of many subjects and professional knowledge, for example mechanism, electrician, electron, numerical control, auto control and computer application.
My design subject is DK7732 numerical control electrical-discharge perforation molding machining tool. DK means numerical control machining tool. 77 means wire electrical-discharge perforation molding machining tool. 32 means the width of tool’s worktable.
The design contains collectivity distribution design, landscape orientation feed design, portrait feed design, circumgyrate worktable design. It still includes intension calculation of gear wheel, the checking of ball bearing pole and the calculation of axis gearing life-span. The controlling system part contains the circuit of step-by-step electromotor control and the circuit of pulse electrical source. This part is the most important part of numerical control electrical-discharge machining tool, and it is very hard for me. The design of step-by-step electromotor control includes hardware circuit design and software system design. It explains the enlarging of CMOS chip and the design of keyboard display interface. The circuit is composed by transistor and unattached elements, it exports high and low voltage pulse, which can apply with two electrical-discharge interval and improve productivity.
Key words: Numerical control wire electrical-discharge machining, principle axis motion, step-by-step electromotor, pulse electrical source
目錄
引言………………………………………………………………………………(1)
一 總體方案設計……………………………………………………………(2)
(一) 總體方案的擬定…………………………………………………………(2)
(二) 主要技術參數(shù)的確定……………………………………………………(2)
二 儲絲走絲部件結構設計………………………………………………(3)
(一) 儲絲走絲部件運動設計…………………………………………………(3)
1.對高速走絲機構的要求………………………………………………………(3)
2.高速走絲機構的結構及特點…………………………………………………(4)
(二) 儲絲走絲部件主要零件強度計算………………………………………(10)
1.齒輪傳動比的確定……………………………………………………………(10)
2.齒輪齒數(shù)的確定………………………………………………………………(10)
3.傳動件的估算…………………………………………………………………(12)
4.齒輪模數(shù)估算…………………………………………………………………(13)
5. 齒輪模數(shù)的驗算………………………………………………………………(14)
(三) 儲絲走絲部件主要零件強度驗算………………………………………(16)
1.齒輪強度的驗算………………………………………………………………(16)
2.主軸的驗算……………………………………………………………………(19)
(四) 主軸組件結構設計………………………………………………………(21)
1.軸承配置形式…………………………………………………………………(21)
2.主軸組件的調(diào)整和預緊………………………………………………………(22)
三 進給傳動設計……………………………………………………………(22)
(一) 進給傳動運動設計………………………………………………………(22)
1. 脈沖當量和傳動比的確定……………………………………………………(22)
(二)滾珠絲桿螺母副的型號選擇和滾珠絲桿的選型和校核…………………(23)
1. 滾珠絲桿螺母副的型號選擇…………………………………………………(23)
2. 滾珠絲桿的選型和校核………………………………………………………(25)
(三)步進電機的選擇……………………………………………………………(28)
1.根據(jù)脈沖當量和最大靜轉矩初選電機型號…………………………………(28)
2.啟動矩頻特性校核……………………………………………………………(30)
(四)進給機構支承設計…………………………………………………………(31)
1. 螺桿的支承形式………………………………………………………………(31)
2. 螺桿的支承方式………………………………………………………………(31)
四 數(shù)控系統(tǒng)設計……………………………………………………………(32)
(一)高頻脈沖電源………………………………………………………………(32)
(二)數(shù)字控制系統(tǒng)設計………………………………………………………(33)(三)控系統(tǒng)硬件的電路設計……………………………………………………(34)
1. 單片機設計……………………………………………………………………(34)
2. 系統(tǒng)擴展………………………………………………………………………(38)
3. I/O 口的擴展…………………………………………………………………(42)
4. 顯示器的接口設計……………………………………………………………(48)
5. 步進電機控制電路設計………………………………………………………(50)
6. 光電隔離電路設計……………………………………………………………(57)
7. 部分控制程序…………………………………………………………………(58)
8. 其他接口電路設計……………………………………………………………(70)
參考文獻…………………………………………………………………………()
謝辭………………………………………………………………………………()