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In the fine processing of automotive molds, electric machining machines should be the first choice. As the world's top supplier of electrical processing equipment, Swiss Charmilles, with its deep understanding and careful research of EDM machines for half a century, can provide high-quality solutions for high value-added automotive mold processing!
Excellence solution
At present, the requirements for high-grade molds are that the surface texture is clear, that is, the surface is flat, the roughness is uniform, the corners are clear, and the dimensions are matched with strict joints. In order to meet the above requirements, it is necessary to thoroughly study the mechanism of EDM: to ensure that the size of the mold is fine and clear, and the discharge gap of the electromachining equipment must be small, which requires completely solving the chip discharge under small gaps. Difficulties, high servo performance requirements, and smooth machining; when machining complex cavities, the machining difficulty and processing area in different directions vary greatly. In order to ensure the uniformity of the discharge gap under high efficiency, the processing time per unit area should be equal. This requires the use of translational techniques to properly allocate time to digest this unevenness.
1, the problem of chip removal in small gap discharge
In order to solve the problem of concentrated discharge in a small gap, Xia Mier uses a digital full-closed-loop servo system to reliably control the stability of small-gap machining, and the machine's own excellent mechanical design and manufacturing process, so that the machine responds within 2ms. Then a displacement of 10 μm is made in 2 to 4 ms, which is exactly the distance that needs to be pulled from the first discharge to the stable operation in finishing. Since the EDM process removes the metal by means of concentrated discharge, after the first discharge, the flange of the discharge pit and a large amount of electrolytic products may contaminate the gap, resulting in the second discharge also occurring nearby. This will locally produce a series of pulse discharge phenomena until it becomes quite concave. In the finishing process, due to the use of small gap discharge, the electric erosion product diffuses slowly, and the local pollution is more serious, so that the subsequent pulse evolves into an arc, making the depressed portion more rough. Therefore, Charmilles also uses the PILOTEXPERTIII expert system in the machine tool. This high-end artificial intelligence device can correctly and quickly detect each pulse, classify, count and judge them, and use cutting energy pulses and changing pulse parameters. The method effectively improves the pollution status of the concentrated discharge area, and at the same time gives the servo system a clear micro-recovery signal.
The superposition of the digital full-closed-loop servo system and the PILOTEXPERT III expert system fully controls the length of the concentrated discharge pulse train. The earlier the burst is terminated, the better the flatness of the processed profile, but at the same time the problem of low efficiency. Usually, the pulse train is terminated at the end of the arc to be arced, which is the most efficient. Of course, this can be set by the operator according to the requirements of the workpiece drawing.