一、火花機的主要組成部件

火花機也(ye)稱為電火花加工機(ji)(ji)床(chuang)(chuang)或EDM機(ji)(ji)床(chuang)(chuang)，主要組成部件(jian)包(bao)括以(yi)下幾個部分：

1、機床主體

機(ji)床主(zhu)體(ti)(ti)是火(huo)花機(ji)的基礎結構，它承載(zai)著所有的工(gong)作部件(jian)和控制系統。主(zhu)體(ti)(ti)通常(chang)由鑄(zhu)鐵或(huo)鋼(gang)材制成，以確保穩定性(xing)和剛性(xing)。

2、主軸和電極夾持裝置

主軸是安裝和移動電極的部分，用于將電極精確定位在工件上方。電(dian)極夾持裝(zhuang)置(zhi)用于固定(ding)電(dian)極，并確保(bao)電(dian)極在(zai)加工過程中保(bao)持穩定(ding)的(de)位置(zhi)和角度(du)。

3、工作臺和工件夾持裝置

工作臺用于支撐和移動工件，以便在加工過程中精確定位工件。工件夾持裝置用于固定(ding)工件，防止(zhi)在加工過程(cheng)中發(fa)生(sheng)移動(dong)或振動(dong)。

4、電源和控制系統

電源系統為火花機提供所需的電壓和電流，用于產生電火花。控(kong)制(zhi)(zhi)系(xi)統是火花機(ji)的(de)(de)核心部分，它(ta)控(kong)制(zhi)(zhi)電(dian)極和(he)工作臺(tai)的(de)(de)運動，以(yi)及(ji)電(dian)源的(de)(de)通斷，確保加工過程的(de)(de)精確性(xing)和(he)穩定性(xing)。控(kong)制(zhi)(zhi)系(xi)統通常包括(kuo)計算機(ji)數控(kong)（CNC）系(xi)統，用于編程和(he)自動化(hua)加工過程。

5、工作液循環系統

工(gong)作液(ye)在火花加(jia)(jia)工(gong)過程中起到(dao)冷卻、潤滑和(he)(he)清除加(jia)(jia)工(gong)廢屑的作用。工(gong)作液(ye)循環系統負責將工(gong)作液(ye)輸送到(dao)加(jia)(jia)工(gong)區(qu)域，并回收和(he)(he)過濾使(shi)用過的工(gong)作液(ye)。

6、電氣系統和傳感器

電氣系統為火花機提供電力和信號傳輸，確保各個部件的正常運行。傳(chuan)感器用于監測加工(gong)過程中(zhong)的(de)各種參數，如電極(ji)和工(gong)作臺的(de)位置、電流和電壓(ya)等，以便及時(shi)調(diao)整和控制加工(gong)過程。

7、安全防護裝置

火花(hua)機在(zai)工(gong)作過程中(zhong)可(ke)能(neng)會產生火花(hua)和飛濺物，因此需要配備(bei)安全防(fang)護(hu)裝置，如防(fang)護(hu)罩、防(fang)護(hu)門和緊急停機按鈕等，以保護(hu)操作人(ren)員的安全。

二、火花機的工作原理

進行電火花機加工(gong)時(shi)，工(gong)具電(dian)(dian)(dian)極和工(gong)件分別(bie)接脈沖電(dian)(dian)(dian)源的(de)兩極，并浸(jin)入(ru)工(gong)作(zuo)(zuo)液中，或將工(gong)作(zuo)(zuo)液充(chong)入(ru)放電(dian)(dian)(dian)間(jian)(jian)隙(xi)。通過間(jian)(jian)隙(xi)自動控制系(xi)統控制工(gong)具電(dian)(dian)(dian)極向工(gong)件進給，當(dang)兩電(dian)(dian)(dian)極間(jian)(jian)的(de)間(jian)(jian)隙(xi)達到一(yi)定(ding)距(ju)離時(shi)，兩電(dian)(dian)(dian)極上施加的(de)脈沖電(dian)(dian)(dian)壓將工(gong)作(zuo)(zuo)液擊穿，產生(sheng)火花(hua)放電(dian)(dian)(dian)。

在(zai)放(fang)電(dian)(dian)的(de)微細通道中瞬(shun)時集(ji)中大量的(de)熱能，溫度可高達(da)一萬(wan)攝氏度以上(shang)(shang)，壓力也有急劇變化，從而使這一點工(gong)(gong)作表面(mian)局部微量的(de)金屬材料(liao)立刻熔化、氣(qi)化，并爆炸式(shi)地飛(fei)濺到(dao)工(gong)(gong)作液(ye)中，迅速冷凝，形(xing)成固體的(de)金屬微粒，被工(gong)(gong)作液(ye)帶(dai)走。這時在(zai)工(gong)(gong)件表面(mian)上(shang)(shang)便(bian)留下一個(ge)微小的(de)凹(ao)坑痕跡，放(fang)電(dian)(dian)短暫停歇，兩電(dian)(dian)極間(jian)工(gong)(gong)作液(ye)恢復絕緣狀態。

緊接著(zhu)，下一(yi)個脈沖電(dian)壓又在兩電(dian)極相對接近的另一(yi)點處擊穿，產生(sheng)火花放(fang)(fang)電(dian)，重復上述過(guo)程。這(zhe)樣，雖然每個脈沖放(fang)(fang)電(dian)蝕除的金屬(shu)量極少，但因每秒有成(cheng)千上萬(wan)次脈沖放(fang)(fang)電(dian)作用，就(jiu)能(neng)蝕除較多的金屬(shu)，具有一(yi)定(ding)的生(sheng)產率。

在(zai)保持工(gong)(gong)(gong)(gong)(gong)(gong)(gong)具(ju)(ju)(ju)電(dian)(dian)極(ji)(ji)(ji)與工(gong)(gong)(gong)(gong)(gong)(gong)(gong)件(jian)之間恒(heng)定放電(dian)(dian)間隙的(de)條件(jian)下(xia)，一邊(bian)蝕(shi)(shi)除工(gong)(gong)(gong)(gong)(gong)(gong)(gong)件(jian)金(jin)屬(shu)，一邊(bian)使工(gong)(gong)(gong)(gong)(gong)(gong)(gong)具(ju)(ju)(ju)電(dian)(dian)極(ji)(ji)(ji)不斷地向工(gong)(gong)(gong)(gong)(gong)(gong)(gong)件(jian)進(jin)給，最(zui)后便加工(gong)(gong)(gong)(gong)(gong)(gong)(gong)出與工(gong)(gong)(gong)(gong)(gong)(gong)(gong)具(ju)(ju)(ju)電(dian)(dian)極(ji)(ji)(ji)形狀(zhuang)相(xiang)對應的(de)形狀(zhuang)來(lai)。因此，只要改變工(gong)(gong)(gong)(gong)(gong)(gong)(gong)具(ju)(ju)(ju)電(dian)(dian)極(ji)(ji)(ji)的(de)形狀(zhuang)和工(gong)(gong)(gong)(gong)(gong)(gong)(gong)具(ju)(ju)(ju)電(dian)(dian)極(ji)(ji)(ji)與工(gong)(gong)(gong)(gong)(gong)(gong)(gong)件(jian)之間的(de)相(xiang)對運動方(fang)式，就能加工(gong)(gong)(gong)(gong)(gong)(gong)(gong)出各種復雜的(de)型面。工(gong)(gong)(gong)(gong)(gong)(gong)(gong)具(ju)(ju)(ju)電(dian)(dian)極(ji)(ji)(ji)常用導電(dian)(dian)性(xing)良好、熔點較高、易(yi)加工(gong)(gong)(gong)(gong)(gong)(gong)(gong)的(de)耐電(dian)(dian)蝕(shi)(shi)材料，如(ru)銅、石墨(mo)、銅鎢(wu)合(he)金(jin)和鉬(mu)等。在(zai)加工(gong)(gong)(gong)(gong)(gong)(gong)(gong)過(guo)程中(zhong)，工(gong)(gong)(gong)(gong)(gong)(gong)(gong)具(ju)(ju)(ju)電(dian)(dian)極(ji)(ji)(ji)也有損耗(hao)，但小于工(gong)(gong)(gong)(gong)(gong)(gong)(gong)件(jian)金(jin)屬(shu)的(de)蝕(shi)(shi)除量，甚至接近(jin)于無損耗(hao)。

工(gong)作(zuo)液(ye)作(zuo)為放(fang)(fang)(fang)電(dian)(dian)(dian)介(jie)質(zhi)，在(zai)加(jia)(jia)工(gong)過程(cheng)中還起(qi)著冷卻、排屑等作(zuo)用(yong)(yong)。常(chang)(chang)用(yong)(yong)的(de)(de)(de)工(gong)作(zuo)液(ye)是(shi)(shi)粘度較低、閃點(dian)較高、性(xing)能穩定的(de)(de)(de)介(jie)質(zhi)，如煤油(you)、去離(li)子水(shui)和(he)乳化液(ye)等。電(dian)(dian)(dian)火(huo)花機是(shi)(shi)一種(zhong)自激放(fang)(fang)(fang)電(dian)(dian)(dian)，其(qi)特(te)(te)點(dian)如下：火(huo)花放(fang)(fang)(fang)電(dian)(dian)(dian)的(de)(de)(de)兩(liang)個(ge)電(dian)(dian)(dian)極(ji)間(jian)(jian)在(zai)放(fang)(fang)(fang)電(dian)(dian)(dian)前具較高的(de)(de)(de)電(dian)(dian)(dian)壓，當(dang)兩(liang)電(dian)(dian)(dian)極(ji)接(jie)近時(shi)，其(qi)間(jian)(jian)介(jie)質(zhi)被擊穿后，隨(sui)(sui)即發生火(huo)花放(fang)(fang)(fang)電(dian)(dian)(dian)。伴隨(sui)(sui)擊穿過程(cheng)，兩(liang)電(dian)(dian)(dian)極(ji)間(jian)(jian)的(de)(de)(de)電(dian)(dian)(dian)阻急劇變小(xiao)，兩(liang)極(ji)之間(jian)(jian)的(de)(de)(de)電(dian)(dian)(dian)壓也隨(sui)(sui)之急劇變低。火(huo)花通(tong)道(dao)必須在(zai)維(wei)持暫(zan)短的(de)(de)(de)時(shi)間(jian)(jian)（通(tong)常(chang)(chang)為10-7-10-3s）后及時(shi)熄滅，才可保持火(huo)花放(fang)(fang)(fang)電(dian)(dian)(dian)的(de)(de)(de)“冷極(ji)”特(te)(te)性(xing)（即通(tong)道(dao)能量轉換的(de)(de)(de)熱能來(lai)不及傳至電(dian)(dian)(dian)極(ji)縱深），使通(tong)道(dao)能量作(zuo)用(yong)(yong)于(yu)極(ji)小(xiao)范(fan)圍。通(tong)道(dao)能量的(de)(de)(de)作(zuo)用(yong)(yong)，可使電(dian)(dian)(dian)極(ji)局部(bu)被腐(fu)蝕。利用(yong)(yong)火(huo)花放(fang)(fang)(fang)電(dian)(dian)(dian)時(shi)產生的(de)(de)(de)腐(fu)蝕現象對(dui)材料進行尺寸加(jia)(jia)工(gong)的(de)(de)(de)方法，叫電(dian)(dian)(dian)火(huo)花機加(jia)(jia)工(gong)。