This paper concerns with a machining experiment on the beryllium sample by electrical discharge machining (EDM), and the experiment proves the machinability in beryllium foil machining of EDM. A brass electrode was chosen for the machining, and the relationship between the tool wear and the process condition was revealed. By the alternation of the positive polarity machining and the negative polarity machining, the tool wear caused by electric erosion was furthest controlled. The foil with a thickness of (0.05~0.06) mm was achieved, and the Ra
of (0.18~0.20) μm and the P-V value of 0.78 μm were measured through white-light interference.
In this paper, the process parameters such as the diameter of the cups, the rotation speed of the cups, and the lapping pressure are optimized through the simulation analysis of the lapping process parameters in the four cup lapping action and the analysis of the statics of the beryllium rotor. A four cup lapping platform for a beryllium rotor was built, and the four-axis motion control was realized through a programming method based on LabVIEW. Cups with three surface materials were developed by using vapor deposition and other methods, and lapping experiment were conducted for cups with different materials and granularity. Finally, a beryllium rotor with a surface roughness of 80nm was obtained through the design and processing of the process route, and an ultra-precision lapping process for the ESG beryllium rotor was obtained.
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