The research is aimed at expanding the technological capabilities of electrical processing methods through the use of programming systems for the technical characteristics of electrode tools (EI) directly in a digital model with their subsequent production by additive methods. The article discusses the issues of obtaining parts of complex shape. This is realized by the method of preliminary 3D printing of the electrode-tool with subsequent metallization of the working surfaces, which excludes finishing with the use of expensive equipment. However, the process of designing such a tool is associated with the complexity of its implementation for the conditions of a single or pilot production. The approach proposed by the authors to the design and manufacture of a complex-shaped combined EI makes it possible to significantly reduce its cost, especially at the stage of debugging the technological process in the conditions of launching the product into production.

Purpose of research is to develop a methodology that allows designing EDM electrodes applying advanced computer-aided design (CAD) systems by forming the tool’s working surface with geometry which is inverse equidistant to the geometry of a given workpiece taking into account the EDM gap, working translation or translation-rotational motion of EDM electrodes, the value of the layer of conductive coating based on the technological parameters of the processing procedure. It is also necessary to propose, implement and formulate technological guidelines for manufacturing EDM electrodes from dielectric materials by additive techniques with the subsequent formation of a conductive layer on them; the value of the layer should ensure the flow of working electrical processes in the EDM gap and the necessary tool life. This will make it possible to expand the scope of application of combination EDM electrodes as applied to combined processing techniques which are characterized by a wide variety of working surface shapes, which correspond to the geometry of the workpiece, which is not limited by the degree of curvature, has by far lower cost and high processability when creating a special tool for pilot and single manufacturing.Methods. When carrying out the work, theory of the classical laws of mechanical engineering technology, electrical processing techniques, the known laws of rapid prototyping and additive technologies were used.Results. The theoretical foundations and the technology for manufacturing combination EDM electrodes by rapid prototyping have been developed and a methodology for calculating and designing the working part of EDM electrodes has been proposed taking into account the geometric parameters of the machined surface and a variable EDM gap value.Conclusion. The mechanism of EDM electrode design by means of digital prototyping in modern CAD systems is justified taking into account the features of the workpiece geometry, EDM gap and metallization material.

Описаны возможности и результаты применения современных САПР для автоматизации процесса получения формы параметрического инструмента на примере проектирования и изготовления комбинированного электрода-инструмента для электрических методов обработки.

The research is aimed at modernizing the technology of designing and manufacturing an electrode instrument for electrical processing methods in order to reduce costs in terms of experimental design and individual production. In this regard, the article is aimed at disclosing the possibilities of using modern computer-aided design tools and rapid prototyping technology for the manufacture of a complex profile tool for individual and experimental production. The materials of the article are of practical value for enterprises of the machine-building complex, as they allow making changes in the technology of designing and manufacturing electrode tools for electrical processing methods and using modern computer-aided design systems and additive technologies that reduce the cost and increase the variability of its application.

Актуальность исследования обоснована расширением функциональных возможностей современных систем автоматизированного проектирования, которые включают в себя не только средства автоматизации большей части жизненного цикла изделия, но и применение облачных технологий, что существенно расширяет возможности их применения. В связи с этим статья направлена на раскрытие особенности применения современных средств автоматизированного проектирования и аддитивных технологий для изготовления сложных деталей или элементов конструкций в условиях единичного и опытного производства, когда необходимо проведение теоретических и экспериментальных исследований на основе проектирования и разработки сложнопрофильного электрод-инструмента для электрических методов обработки. В статье представлен метод проектирования и производства электрода-инструмента для электрических методов обработки с последующим нанесением токопроводящего покрытия, с использованием современных систем автоматизированного проектирования в опытно-конструкторском и единичном производстве. Материалы статьи представляют практическую ценность для предприятий машиностроительного комплекса, так как позволяют производить изменения технологии проектирования и изготовления сложных деталей или элементов конструкций. За счет применения современные системы автоматизированного проектирования и аддитивные технологии, что снижает себестоимость и повышает вариативность его применения The relevance of the study is justified by the expansion of the functionality of modern automated design systems, which include not only automation tools for most of the product life cycle but also the use of cloud technologies, which significantly expands the possibilities of their application. In this regard, the article is aimed at disclosing the features of the use of modern means of automated design and additive technologies for the manufacture of complex parts or structural elements in a single and pilot production, when it is necessary to conduct theoretical and experimental research based on the design and development of a complex-profile electrode-tool for electrical processing techniques. The article presents a method for designing and producing a tool-electrode for electrical processing methods, followed by the application of a conductive coating, using modern computer-aided design systems in experimental design and unit production. The materials of the article are of practical value for enterprises of the machine-building complex since they allow making changes in the design technology and manufacturing of complex parts or structural elements. Through the use of modern computer-aided design systems and additive technologies the cost reduces and the variability of its application increases