Abstract Compensation of tool wear in micro-EDM milling of inclined surfaces is a difficult task due to variations of the radial engagement conditions of the tool with the workpiece. Traditional compensation methods based on off-line wear prediction are likely to be inaccurate, while methods involving tool measurements are time-consuming. In this research, the process dynamics when the tool is not fully engaged with the workpiece are investigated by performing repeated milling tests and analysing the effects on the discharging process and tool wear behaviour. An adaptive tool wear compensation strategy is accordingly developed, combining traditional linear compensation method (LCM) and tool wear sensing. In this strategy, simultaneous monitoring of the normal discharge pulses and tool displacement is used for determining the tool engagement conditions. This allows to adapt the milling process to the expected tool wear behaviour when the tool is in partial engagement. The proposed control strategy has been tested for an industrially-relevant case, i.e. the shaping of a diffuser for a turbine blade. A machining accuracy in the range of the applied milling layer thickness was obtained without the need of tool measurements.

中文翻译：

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微细电火花铣削中局部刀具啮合的影响和自适应刀具磨损补偿策略对斜面高效铣削的影响

摘要 由于刀具与工件径向啮合条件的变化，斜面微细电火花铣削刀具磨损补偿是一项艰巨的任务。基于离线磨损预测的传统补偿方法可能不准确，而涉及刀具测量的方法非常耗时。在这项研究中，通过执行重复铣削试验和分析对放电过程和刀具磨损行为的影响，研究了刀具未与工件完全啮合时的过程动力学。相应地开发了一种自适应刀具磨损补偿策略，结合了传统的线性补偿方法 (LCM) 和刀具磨损传感。在这个策略中，同时监测正常放电脉冲和刀具位移用于确定刀具啮合条件。这允许在刀具部分接合时使铣削过程适应预期的刀具磨损行为。所提出的控制策略已经针对工业相关情况进行了测试，即涡轮叶片扩散器的成形。无需工具测量即可获得在应用铣削层厚度范围内的加工精度。