Abstract
To guarantee limited fluctuation of interelectrode gap (IEG) size during whole pulse electrochemical machining (PECM) process, a tool feeding control algorithm based on a realtime gap size predictive model is proposed. Firstly, a theoretical model for IEG size detection is built based on Ohm's and Faraday's laws. Then, an experimental system is developed to validate and adjust the model which can online predict the IEG size. Finally, a tool feeding control algorithm based on a new digital differential analyzer (DDA) interpolator composed of two adders is proposed to compensate the front gap change and limit the fluctuation of IEG size in process. Application results show that the new DDA interpolator could online adjust the moving direction and position of Z axis correctly according to the results of the detecting model. And, the proposed method could achieve dimensional accuracy and surface roughness of industrial application for a slot in PECM.
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