In laser beam cutting and laser piercing process, the machining speed and quality are very sensitive to the flow of assist gas and laser beam focusing position. In order not only to improve the cutting speed and the removal capability of the molten material and to save the consumption of the gas flow in laser beam cutting, but also to realize high speed piercing of high aspect-ratio holes, a magnetic-levitated (maglev) lens driving actuator was proposed and fabricated. The actuator can drive the lens to achieve real-time positioning control of the relative radial displacement between the lens axis and the assist gas jet nozzle axis (off-axis control) in radial directions in a range of ±1mm within 1.5 μm of tracking error and bandwidths more than 150Hz, and to achieve real-time positioning control of laser beam focusing point in axial direction in a range of ±5mm within 3 μm of tracking error and bandwidth more than 100Hz.
Electrical discharge machining has the capability of machining all conductive materials regardless of hardness, and has the ability to deal with complex shapes. However, the speed and accuracy of conventional EDM are limited by probability and efficiency of the electrical discharges. This paper describes a three degrees of freedom (3-DOF) controlled, wide-bandwidth, high-precision, long-stroke magnetic drive actuator. The actuator can be attached to conventional electrical discharge machines to realize a high-speed and high-accuracy EDM. The actuator primarily consists of thrust and radial magnetic bearings, thrust and radial air bearings and a magnetic coupling mechanism. By using the thrust and radial magnetic bearings, the translational motions of the spindle can be controlled. The magnetic drive actuator possesses a positioning resolution of the order of micrometer, a bandwidth greater than 100Hz and a positioning stroke of 2mm.
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