At present, most domestic high speed molybdenum wire cutting machine tools do not perform systematic and comprehensive process tests and establish a corresponding process database. Various types and specifications of high-speed wire cutting machines are incompatible from hardware to command codes, and there is no unified standard for them. Moreover, due to the different boundary conditions of the machine tools, the relationship between the processing parameters and the process effects varies. In addition, the wire cutting process is random and complex, and involves many interference factors. All of these make it difficult to establish a simulation system that can be applied to various types and sizes of high-speed molybdenum wire -cutting machine tools.
In order to make the developed simulation system versatile, it can be realized by training the model function. Different high speed wire cutting machines have different machine characteristics. Under the set processing conditions, a corresponding process database (ie, a sample bank) is established. Using the BP network to learn a new sample library, the wire cutting process simulation model under this condition can be obtained. On this basis, the process effect can be predicted; at the same time, the simulated annealing algorithm is used to optimize the process parameters and the optimum processing parameters can be given. The implementation of the universality of the simulation system is shown in Figure 6-14.
The training model mainly includes three parts: inputting machine tool process parameter code, setting process conditions and process database management. For the molybdenum wire cutting machine tool used by the user, under the set process conditions, a simulation model of the high speed wire cutting process that meets the user’s requirements is established for the corresponding process data sample.
(1) Machine tool process code. The main parameters for user adjustment of high speed molybdenum wire cutting machine are pulse width, pulse interval and pulse peak current. Pulse parameter adjustment adopts digital display and level adjustment, which is very convenient and intuitive. Different machine models, the actual value corresponding to the pulse parameter code is different. The pulse interval code corresponds to the actual value on some machine tools, and the ratio of pulse interval to pulse width on other machine tools can be selected according to the user’s machine tool.。
Figure 6-15 shows the interface of the process parameter code of the input machine tool. The user selects the pulse parameter through the radio button, and adds the corresponding pulse parameter code and the corresponding actual value by “increasing code”. If it needs to be modified, first select the item to be modified.”Delete code” deletes this item. In addition, the value corresponding to the pulse interval code is determined according to the machine tool used by the user. If the pulse interval code corresponds to the actual value, “Pulse Interval/Pulse Width” is not selected; if it corresponds to the ratio of the pulse interval to the pulse width, then select Pulse Interval/Pulse Width. After the user determines the molybdenum wire machine tool parameter code, the simulation system automatically converts the process parameter code to the corresponding value according to the machine characteristics.
(2) Processing conditions. The user sets the process conditions for performing the process test through the interface shown in Figure 6-16: workpiece material, power output voltage, electrode molybdenum wire diameter, electrode wire take-off speed, working fluid name, and working solution concentration. For the set processing conditions, establish a corresponding simulation model。
Figure 6 – 16 Processing conditions and process database
(3) Technology database (including data for molybdenum cutting wire). Users can update the process database or open an existing process database through the process database management function. The user conducts a complete process test, obtains typical process data, and establishes a process database (ie, a sample bank). Through the training of the sample library, the simulation model of the wire cutting process can be obtained. If you need to further improve the accuracy of the model, you can open the existing technology database, add new learning samples, use the BP network to re-learn new samples, and continuously improve the model accuracy. According to the author’s experience, when the process data sample is normally distributed, the model accuracy after training is higher。
Figure 6-16 shows the interface to the new database. The user enters the process data sample by “adding data”, in which the pulse width t intimidates the pulse interval to and the pulse peak current i, and the input value is the process parameter code of the corresponding machine use molybdenum wire as electrode. Workpiece thickness H, surface roughness Ra, and cutting speed are actual values in units of mm, μ.m, and rnm 2 /min, respectively. You can use Delete Data to delete some data that needs to be modified. After the process database is established, the system stores it in the data file. If the process database needs to be updated, the system opens the corresponding data file for operation
The user enters the process parameter code of the machine tool, sets the processing process conditions, and establishes the process database. The simulation system starts the training model and establishes an artificial neural network model that meets the user’s requirements for the molybdenum wire cutting process.
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