Research On Electrode Wear Compensation For Micro-EDM Milling

Micro-electro-discharge machining(Micro-EDM) milling is a kind of electric machining, it is a non-contact machining because there is no direct contact between the tool electrode and workpiece when it works, so it is ofen used for the micro-parts machining which is high hardness, high brittleness, high viscosity and high purity. And Micro-EDM can machine all kinds of conductive materials when it using small energy discharge pulse for power supply.As Micro-EDM milling cannot avoid electrode wear, electrode wear is the most important factor which product a lot of machining error. In this study, a compensation method for a micro-EDM process using fuzzy control technique is proposed. This new method is based on uniform loss rule and fixed-length wear compensation, using fuzzy control technique to improve effectiveness and machining precision relative to the single offline and online wear compensation method. The new method can intelligently setting a new offline and online wear compensation by comparing relative error and relative error rate of wear which obtained by online detection.Do a research on CNC(Computer Numerical Control) system of micro-EDM milling, and successfully design a six-axis CNC based on PMAC which designed by Delta Tau company and MFC which designed by Microsoft. The compensation experiment result confirms this method can improve the machining effectiveness and machining precision compare to the single offline and online wear compensation method.