中文摘要：

用电火花加工技术快速加工大深径比微小孔存在散热困难、排屑不畅、电极损耗大及加工过程不易控制等技术难点,为此,在分析电火花加工机理及加工特点的基础上,研发了一台用于快速加工大深径比微小孔的电火花机床。该设备采用立式布局,通过应用电极旋转、工件振动的旋振式机构,实现了加工过程中快速散热和排屑;通过采取工业控制计算机搭载数据采集卡和运动控制器的方式,实现了加工过程的检测控制功能一体化。针对电火花加工过程中放电信号严重畸变以及放电状态不稳定导致加工状态难检测的问题,提出了两级模糊逐级映射放电状态检测方法,同时为了实现机床的快速响应和精确控制,设计了双闭环加工控制系统。实验表明,该机床适合于深径比超过10,小孔直径为60～200μm的微小孔快速加工,且性能稳定、可靠性高。

英文摘要：

To overcome the shortcomings in rapidly machining micro and small holes with a high-aspect-ratio by Electric Discharge Machine（EDM）, such as slow cooling, poor debris flushing, high tool wear and complex manipulation, a rapid EDM machine for micro and small holes is developed based on analyzing the mechanics and characteristics of EDM. Laid up vertically,the machine applies a rotaryvibrate mechanism with tool rotating and workpiece vibrating to the rapid cooling and debris flushing, and adopts an industrial PC （IPC） with PCI card and PMAC card plugged to acquire data to implement the integratization of machining and testing. In order to solve the problem that discharge states are difficult to detect due to severely distorting sparking signals and unstable sparking states in EDM, a successive mapping detection method of discharge states based on two-stage fuzzy logic is proposed and a double-closed-loop control system is designed to achieve rapid response and precise control of the working process. Experiments show that this machine is suitable for rapidly manufacturing the micro and small holes with high-aspect-ratio （〉10） and diameters from 60μm to 200μm and has stable performance and high reliability.