Adaptive servo sensitivity control algorithm for EDM of shrouded blisks

Multi-axis electrical discharging machining (EDM) is the most commonly used manufacturing method for shrouded blisks. The discharge points and discharge gap distance are time-varying in a multi-axis EDM process. It is difficult to obtain an optimal servo feedrate. In traditional multi-axis EDM servo...

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Bibliographic Details
Published inInternational journal of advanced manufacturing technology Vol. 130; no. 1-2; pp. 837 - 849
Main Authors Sun, Yan-Xin, Xi, Xue-Cheng, Zhao, Wan-Sheng
Format Journal Article
LanguageEnglish
Published London Springer London 01.01.2024
Springer Nature B.V
Subjects
Adaptive control
Advanced manufacturing technologies
Algorithms
Arc discharges
Blisks
CAE) and Design
Circuits
Computer-Aided Engineering (CAD
Control algorithms
Control theory
Efficiency
Electric arcs
Electric discharge machining
Electrodes
Engineering
Industrial and Production Engineering
Manufacturing
Material removal rate (machining)
Mechanical Engineering
Media Management
Multiaxis
Optimization
Original Article
Parameter estimation
Production methods
Sensitivity
Servocontrol
Variance analysis
Servo sensitivity
Shrouded blisks
Machining efficiency
Multi-axis EDM
Adaptive control
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ISSN0268-3768
1433-3015
DOI10.1007/s00170-023-12763-6

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Summary:Multi-axis electrical discharging machining (EDM) is the most commonly used manufacturing method for shrouded blisks. The discharge points and discharge gap distance are time-varying in a multi-axis EDM process. It is difficult to obtain an optimal servo feedrate. In traditional multi-axis EDM servo control systems, servo sensitivity is usually chosen as a smaller constant to avoid arc discharges. Thus, the servo feedrate is lower than the material removal rate in a machining process. The open circuit rate is high and the machining efficiency is decreased. This paper proposes an adaptive servo sensitivity control algorithm for multi-axis EDM of shrouded blisks. Servo sensitivity is adjusted according to discharge status, so as to decrease the open circuit rate and to improve the machining efficiency. Experiment results show that the proposed adaptive servo sensitivity control algorithm can improve the machining efficiency of shrouded blisks by 28.02% without deteriorating surface integrity.
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ISSN:0268-3768
1433-3015
DOI:10.1007/s00170-023-12763-6