Abnormal problem and analysis of EDM in mold manufacturing (2)

b. The effect of actual electrode size and translational control. When electrode translation is not used, the actual size of the electrode plays a decisive role in the size of the finished part. After the electrode spark position is correctly determined, a reasonable processing method should be used to ensure the accuracy of the electrode. In the case of electrode translation, the control of the translational amount plays a decisive role in the machining size. According to the measured size of the electrode, the correct translational amount should be determined to ensure that the processing size meets the requirements.

c. The effect of electrode correction accuracy. The size after processing has a great relationship with the accuracy of the correction of the electrodes. The correction deviation of the electrode will increase the vertical plane projection area in the machining feed direction, so that the size of the processed portion is larger than the normal value. Therefore, there is generally a case where the side gap after processing with a small electrode is slightly larger than the side gap after processing with a large electrode. Because the correction accuracy of the small electrode is not as high as that of the large electrode. It is one of the most important conditions to ensure the correct processing size to ensure the correct accuracy of the electrode is the most important part of the EDM process.

d. The influence of electrical parameter adjustment factors. Electrical parameter adjustment is directly related to the actual spark position in the process. Changing the parameters of the electrical parameters will affect the size of the spark gap. The most obvious influence on the spark gap is the current, and the spark gap increases with the increase of the current. The same is true for the effect of pulse width. An increase in the pulse gap will make the spark gap smaller, but the effect is not very obvious. Other relevant parameters also indirectly affect the size of the spark position. Therefore, it is necessary to select reasonable when adjusting the electrical parameters. When changing the electrical parameters, it is necessary to clarify the influence on the processing size.

e. The effect of electrode loss during processing. Electrode loss is inevitable during processing, and the electrode loss causes the finished size to be smaller than the standard value. (The cause of abnormally large electrode loss is detailed below.) The electrode loss must be properly controlled to ensure that the size of the process meets the standard.

f. The impact of machining depth control. The depth in which the feed direction is machined in the machining dimension is a particularly important dimension. The depth control accuracy is related to the processing size. The factors that affect the accuracy of the depth control are first of all the effect on the accuracy of the tool before machining. If there is any foreign matter between the electrode and the workpiece during the tool setting, the tool will be deviated, and the depth of the machining is usually less than the standard value. Therefore, it is necessary to ensure the cleanness between the two poles when setting the knife. The second is the effect of the reserved machining allowance. The size control of the side of the machined part is determined by the spark position of the electrode. The depth control is determined by the depth of the depth to be processed during processing. The selection of the reservation is the same as the selection of the spark position of the electrode. Again, it is the effect on the accuracy of the tool reference. The part of the electrode used to set the knife must be a clear reference, and the reference surface should be smooth and flat. Finally, we must pay attention to the influence of the thermal expansion of the electrode in the roughing process, making it longer than the margin reserved for finishing, so that the processing depth is deeper, and the phenomenon of repairing during finishing is not obvious.

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