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Adaptive servo sensitivity control algorithm for EDM of shrouded blisks

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Abstract

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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Data availability

The datasets used or analyzed during the current study are available from the corresponding author on reasonable request.

Code availability

This paper uses proprietary software and will not be available.

Abbreviations

K :

Servo adjustment constant

MRR :

Material removal rate

N de :

Number of discharge pulses in 1 s

N open :

Number of open circuit pulses in 1 s

N short :

Number of short circuit pulses in 1 s

N spark :

Number of normal discharge pulses in 1 s

r open :

Open circuit ratio in 1 s

r open,A :

Average open circuit ratio in a machining process

r open,i :

Open circuit discharge ratio in the ith second of a machining process

r short :

Short circuit ratio in 1 s

r short,A :

Average short circuit ratio in a machining process

r short,i :

Short circuit ratio in the ith second of a machining process

r spark :

Normal discharge ratio in 1 s

r spark,A :

Average normal discharge ratio in a machining process

r spark,i :

Normal discharge ratio in the ith second of a machining process

S :

Area of a machining surface

S F :

Servo speed

S F ’ :

Estimated servo feedrate

S S :

Servo sensitivity

T machine :

Total time of a machining process

U :

Gap voltage

U ref :

Servo reference voltage

θ :

Estimated parameter vector of the parameter estimation model

φ :

Observation vector of the parameter estimation model

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Funding

This research is financially supported by the National Natural Science Foundation of China (No. 52075333).

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Authors and Affiliations

  1. State Key Laboratory of Mechanical System and Vibration, School of Mechanical Engineering, Shanghai Jiao Tong University, 800 Dongchuan RD, Shanghai, 200240, China

    Yan-Xin Sun, Xue-Cheng Xi & Wan-Sheng Zhao

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  1. Yan-Xin Sun
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  2. Xue-Cheng Xi
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  3. Wan-Sheng Zhao
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Contributions

Y-XS: conceptualization, methodology, software, validation, formal analysis, writing — original draft and editing. X-CX: funding acquisition, supervision, writing — review and editing. W-SZ: supervision, writing — review and editing.

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Correspondence to Xue-Cheng Xi.

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Sun, YX., Xi, XC. & Zhao, WS. Adaptive servo sensitivity control algorithm for EDM of shrouded blisks. Int J Adv Manuf Technol 130, 837–849 (2024). https://doi.org/10.1007/s00170-023-12763-6

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