复杂模型四轴线电火花线切割实体仿真

对线切割系统的运动和性能进行分析，计算了电极丝的最大倾角，给出了切割时电极丝、夹具和工作台之间不发生干涉碰撞的判断条件。在线切割仿真中，基于实体布尔操作实现了实体切割模型的生成。通过电极丝每步扫掠体的布尔并运算，生成切割全过程的电极丝扫掠体。再通过该扫掠体与毛坯体的布尔差运算，得到仿真实体切割模型。该方法同样适用于锥度体切割时可能出现的电极丝路径交叉的情况。文中最后给出了实例，验证了该方法的正确性。

FOUR-AXIS WIRE-EDM SIMULATION OF COMPLICATED MODELS

In the verification of wire electrical discharge machining (EDM), the motion and the performance of the wire-EDM system are analyzed. The maximum inclining angle of the wire is calculated. The relevant judgment methods are used for the collision between the wire, the fixture, and the machining table. In the wire-EDM simulation, the generated solid model can be used to investigate programming results and to check the machining accuracy. The generation algorithm for the solid model in the simulation is solved based on Boolean operations. The wire swept volume for each cutting step is united to form the entire wire swept volume. Through Boolean subtraction between the stock model and the entire wire swept volume, the solid model in the wire-EDM simulation is generated. The method is also suitable for the wire path intersection occurred in cutting cone-shaped models.Finally, experiments are given to prove the method.