一、火花機的主要組成部件

火花機也(ye)稱為(wei)電火花加工機(ji)床或EDM機(ji)床，主要組成部(bu)件包括以下(xia)幾(ji)個部(bu)分(fen)：

1、機床主體

機床主(zhu)體是火花機的基(ji)礎結構，它承(cheng)載著所有的工作部件和控制系統。主(zhu)體通常由鑄鐵(tie)或鋼材制成(cheng)，以確保穩定(ding)性和剛(gang)性。

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)(dian)極(ji)夾持裝置用于固定(ding)電(dian)(dian)極(ji)，并確保電(dian)(dian)極(ji)在加工過程中保持穩定(ding)的位(wei)置和角度。

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(jian)夾持裝(zhuang)置用于固定工件(jian)，防止在加(jia)工過程(cheng)中發生移(yi)動或振動。

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)制系統(tong)(tong)是火花機的(de)核心(xin)部分，它控(kong)制電(dian)(dian)極和工(gong)作(zuo)臺的(de)運動，以及電(dian)(dian)源的(de)通(tong)斷，確(que)保(bao)加(jia)工(gong)過程(cheng)的(de)精(jing)確(que)性和穩定(ding)性。控(kong)制系統(tong)(tong)通(tong)常包括計算(suan)機數(shu)控(kong)（CNC）系統(tong)(tong)，用(yong)于編程(cheng)和自(zi)動化加(jia)工(gong)過程(cheng)。

5、工作液循環系統

工(gong)(gong)作液(ye)在火花加(jia)工(gong)(gong)過(guo)(guo)程中起到冷(leng)卻、潤滑和清除加(jia)工(gong)(gong)廢(fei)屑的作用。工(gong)(gong)作液(ye)循(xun)環系統負責(ze)將工(gong)(gong)作液(ye)輸(shu)送到加(jia)工(gong)(gong)區域，并回收(shou)和過(guo)(guo)濾使用過(guo)(guo)的工(gong)(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。傳感器用于(yu)監測加(jia)工(gong)(gong)過程(cheng)中的各(ge)種參數，如(ru)電極和(he)工(gong)(gong)作(zuo)臺的位置、電流和(he)電壓等，以(yi)便及時調整和(he)控制加(jia)工(gong)(gong)過程(cheng)。

7、安全防護裝置

火花機在工作(zuo)過程中可(ke)能會產(chan)生火花和(he)飛濺(jian)物，因此需要配備安全防護裝置，如防護罩、防護門和(he)緊急(ji)停機按鈕等，以保護操作(zuo)人員的安全。

二、火花機的工作原理

進行電火花機加工(gong)時(shi)，工(gong)具電極(ji)(ji)(ji)和工(gong)件分別接脈沖(chong)電源的(de)兩極(ji)(ji)(ji)，并(bing)浸入工(gong)作(zuo)液(ye)中，或將工(gong)作(zuo)液(ye)充(chong)入放電間隙。通(tong)過間隙自動控制系統(tong)控制工(gong)具電極(ji)(ji)(ji)向工(gong)件進給(gei)，當(dang)兩電極(ji)(ji)(ji)間的(de)間隙達(da)到(dao)一定距離時(shi)，兩電極(ji)(ji)(ji)上施加的(de)脈沖(chong)電壓將工(gong)作(zuo)液(ye)擊穿，產生火(huo)花放電。

在放(fang)(fang)電的(de)微(wei)細通(tong)道(dao)中瞬時(shi)集中大(da)量(liang)的(de)熱能，溫度(du)可高(gao)達一(yi)(yi)萬攝氏(shi)度(du)以上，壓力也有(you)急(ji)劇變化(hua)，從而使(shi)這(zhe)一(yi)(yi)點工(gong)作表(biao)面(mian)局部(bu)微(wei)量(liang)的(de)金(jin)屬(shu)材料(liao)立(li)刻(ke)熔化(hua)、氣化(hua)，并(bing)爆炸式地飛濺到(dao)工(gong)作液(ye)(ye)中，迅速冷凝(ning)，形成固體的(de)金(jin)屬(shu)微(wei)粒，被工(gong)作液(ye)(ye)帶走(zou)。這(zhe)時(shi)在工(gong)件表(biao)面(mian)上便留(liu)下(xia)一(yi)(yi)個微(wei)小的(de)凹坑痕(hen)跡，放(fang)(fang)電短暫停(ting)歇，兩電極間工(gong)作液(ye)(ye)恢(hui)復(fu)絕緣(yuan)狀(zhuang)態。

緊接著，下一個(ge)脈(mo)沖(chong)電(dian)壓又(you)在兩電(dian)極相(xiang)對接近的(de)另一點處擊(ji)穿(chuan)，產(chan)生火花放電(dian)，重復上述過(guo)程。這樣，雖然每個(ge)脈(mo)沖(chong)放電(dian)蝕(shi)除(chu)(chu)的(de)金屬(shu)量極少，但因每秒有(you)成千上萬(wan)次脈(mo)沖(chong)放電(dian)作用，就能蝕(shi)除(chu)(chu)較多的(de)金屬(shu)，具有(you)一定的(de)生產(chan)率。

在保(bao)持工(gong)(gong)(gong)具(ju)(ju)(ju)電(dian)(dian)(dian)(dian)極(ji)(ji)與工(gong)(gong)(gong)件(jian)之(zhi)間(jian)恒定(ding)放電(dian)(dian)(dian)(dian)間(jian)隙(xi)的條件(jian)下，一邊蝕除工(gong)(gong)(gong)件(jian)金屬，一邊使工(gong)(gong)(gong)具(ju)(ju)(ju)電(dian)(dian)(dian)(dian)極(ji)(ji)不(bu)斷(duan)地向(xiang)工(gong)(gong)(gong)件(jian)進(jin)給，最后便加工(gong)(gong)(gong)出(chu)與工(gong)(gong)(gong)具(ju)(ju)(ju)電(dian)(dian)(dian)(dian)極(ji)(ji)形(xing)狀相(xiang)對應的形(xing)狀來。因此，只(zhi)要(yao)改變工(gong)(gong)(gong)具(ju)(ju)(ju)電(dian)(dian)(dian)(dian)極(ji)(ji)的形(xing)狀和工(gong)(gong)(gong)具(ju)(ju)(ju)電(dian)(dian)(dian)(dian)極(ji)(ji)與工(gong)(gong)(gong)件(jian)之(zhi)間(jian)的相(xiang)對運動方式，就能加工(gong)(gong)(gong)出(chu)各種復雜的型面。工(gong)(gong)(gong)具(ju)(ju)(ju)電(dian)(dian)(dian)(dian)極(ji)(ji)常用(yong)導電(dian)(dian)(dian)(dian)性良好、熔(rong)點(dian)較高、易加工(gong)(gong)(gong)的耐(nai)電(dian)(dian)(dian)(dian)蝕材料，如銅(tong)、石墨、銅(tong)鎢(wu)合(he)金和鉬等。在加工(gong)(gong)(gong)過(guo)程中，工(gong)(gong)(gong)具(ju)(ju)(ju)電(dian)(dian)(dian)(dian)極(ji)(ji)也(ye)有損耗，但小于(yu)工(gong)(gong)(gong)件(jian)金屬的蝕除量，甚(shen)至(zhi)接近(jin)于(yu)無(wu)損耗。

工(gong)作(zuo)液(ye)(ye)作(zuo)為放(fang)(fang)(fang)電(dian)(dian)(dian)(dian)介質，在(zai)加工(gong)過程中還起著(zhu)冷卻、排屑等(deng)作(zuo)用(yong)。常用(yong)的(de)(de)工(gong)作(zuo)液(ye)(ye)是(shi)粘度較(jiao)低(di)、閃點(dian)較(jiao)高、性能穩定的(de)(de)介質，如煤(mei)油、去離子水和乳(ru)化(hua)液(ye)(ye)等(deng)。電(dian)(dian)(dian)(dian)火(huo)(huo)花(hua)機是(shi)一(yi)種自(zi)激放(fang)(fang)(fang)電(dian)(dian)(dian)(dian)，其(qi)特點(dian)如下：火(huo)(huo)花(hua)放(fang)(fang)(fang)電(dian)(dian)(dian)(dian)的(de)(de)兩(liang)(liang)(liang)個電(dian)(dian)(dian)(dian)極(ji)(ji)間在(zai)放(fang)(fang)(fang)電(dian)(dian)(dian)(dian)前具較(jiao)高的(de)(de)電(dian)(dian)(dian)(dian)壓(ya)，當(dang)兩(liang)(liang)(liang)電(dian)(dian)(dian)(dian)極(ji)(ji)接(jie)近時(shi)，其(qi)間介質被(bei)(bei)擊(ji)穿(chuan)后(hou)，隨(sui)即發生火(huo)(huo)花(hua)放(fang)(fang)(fang)電(dian)(dian)(dian)(dian)。伴隨(sui)擊(ji)穿(chuan)過程，兩(liang)(liang)(liang)電(dian)(dian)(dian)(dian)極(ji)(ji)間的(de)(de)電(dian)(dian)(dian)(dian)阻急(ji)劇變小，兩(liang)(liang)(liang)極(ji)(ji)之(zhi)間的(de)(de)電(dian)(dian)(dian)(dian)壓(ya)也隨(sui)之(zhi)急(ji)劇變低(di)。火(huo)(huo)花(hua)通(tong)道必須在(zai)維持暫短的(de)(de)時(shi)間（通(tong)常為10-7-10-3s）后(hou)及(ji)時(shi)熄滅，才可保持火(huo)(huo)花(hua)放(fang)(fang)(fang)電(dian)(dian)(dian)(dian)的(de)(de)“冷極(ji)(ji)”特性（即通(tong)道能量轉換的(de)(de)熱能來不及(ji)傳(chuan)至電(dian)(dian)(dian)(dian)極(ji)(ji)縱深），使通(tong)道能量作(zuo)用(yong)于極(ji)(ji)小范圍(wei)。通(tong)道能量的(de)(de)作(zuo)用(yong)，可使電(dian)(dian)(dian)(dian)極(ji)(ji)局部被(bei)(bei)腐(fu)蝕。利用(yong)火(huo)(huo)花(hua)放(fang)(fang)(fang)電(dian)(dian)(dian)(dian)時(shi)產生的(de)(de)腐(fu)蝕現象對(dui)材(cai)料進行尺寸加工(gong)的(de)(de)方法，叫(jiao)電(dian)(dian)(dian)(dian)火(huo)(huo)花(hua)機加工(gong)。