A Magnetorheological Fluid Dynamic Compensation Electro-Discharge Machining System and Method

Abstract

The present invention belongs to the technical field of precision electrospark machining, and specifically relates to a magnetorheological fluid dynamic compensation electrospark machining system and method. The machining system includes: an electrospark machine bed, a drive motor, an electrode spindle, a pulse electromagnet integrated electrode structure, an auxiliary pulse electromagnet, a controller, a fixture, a workbench, and a magnetorheological fluid circulation system. The present invention uses pulsed magnetic field control to form a solid-state conductive structure of the magnetorheological fluid, establishes a controllable discharge gap in the discharge stage, and utilizes the breakdown of a silicone oil-based carrier medium to achieve non-contact discharge machining; in the intermittent stage of the magnetic field, the magnetorheological fluid restores its liquid properties, and synchronously achieves efficient discharge of erosion products, active cooling of the machining area, and micro-abrasive assisted surface finishing through directional flow. This method combines the coordinated control of magnetic field intensity and pulse timing to achieve dynamic reconstruction and compensation of the conductive structure, effectively solving the problem of electrode loss compensation.

Description

Technical Field

[0001] The present invention relates to the technical field of precision electric spark machining, and more particularly to a magnetorheological fluid dynamic compensation electric spark machining system and method. Background Art

[0002] Electrical discharge machining (EDM), a non-contact specialty machining technology, plays an irreplaceable role in the machining of high-hardness materials and complex microstructures in fields such as aerospace and medical devices. However, traditional EDM relies on solid metal electrodes as tool electrodes, a core issue of which is the irreversible loss of electrode material. During the discharge process, the electrode surface gradually deforms due to the continuous erosion of the high-temperature plasma, resulting in dynamic changes in the machining gap, which in turn leads to reduced machining accuracy and deterioration of surface roughness.

[0003] To alleviate the problem of electrode loss, existing technologies primarily focus on optimizing electrode materials, controlling loss compensation, and improving dielectrics. For example, the use of high-melting-point alloys (such as copper-tungsten alloys) or surface coatings can reduce electrode loss, but this comes at the expense of high material costs and limited processing efficiency. Compensation methods that detect electrode loss in real time and adjust the machining path can partially correct geometric errors, but are limited by detection accuracy and response speed, making dynamic micron-level compensation difficult to achieve. Furthermore, while fluid technologies that utilize electrolytes or gaseous media to assist in chip removal can improve the inter-electrode environment, they cannot directly replace the function of solid electrodes, and the insufficient dielectric conductivity reduces discharge energy utilization. Summary of the Invention

[0004] The purpose of the present invention is to overcome the deficiencies of the prior art and to provide a magnetorheological fluid dynamic compensation EDM system and method based on pulsed magnetic field control.

[0005] Magnetorheological fluid (MRF) is an intelligent material composed of a non-magnetic base fluid, micron-sized magnetic particles, and additives (dispersants, stabilizers). Its core characteristic is that it can rapidly (milliseconds) reversibly change its rheological behavior through an applied magnetic field. In the absence of a magnetic field, it is liquid. When a magnetic field is applied, the magnetic particles form chain-like or network-like structures, exhibiting solid-like properties, and the shear yield stress can be increased by several orders of magnitude. This unique controllable "liquid-to-solid" transition has led to its widespread application in mechanical engineering, precision machining, and intelligent control, such as in dampers, clutches, and polishing devices. In particular, it can achieve nanometer-level surface accuracy in precision finishing, while also offering fast response, low energy consumption, and high reliability.

[0006] In the field of finishing, magnetorheological fluid technology is mostly focused on the polishing field, but its innovative applications in electrospark machining are rare. The combination of traditional electrospark machining and magnetorheological fluid technology is expected to break through core problems such as electrode loss, chip removal efficiency and surface quality: The present invention proposes an electrospark machining method based on dynamic compensation of magnetorheological fluid, subverts the traditional electrode form, replaces the rigid metal electrode with magnetorheological fluid, and dynamically reconstructs the conductive layer through the magnetic field to eliminate the electrode loss problem; combines pulsed magnetic field and fluid dynamics to achieve real-time closed-loop control of the discharge gap, and simultaneously solves the chip removal problem through high-speed flushing; integrates discharge etching and abrasive grinding to significantly reduce surface roughness.

[0007] The technical solution adopted in the present invention is:

[0008] The first aspect of the present invention is to provide a magnetorheological fluid dynamic compensation electro-discharge machining system, comprising: an electro-discharge machine bed, a drive motor, an electrode spindle, an integrated pulse electromagnet electrode structure, an auxiliary pulse electromagnet, a controller, a fixture, a workbench, and a magnetorheological fluid circulation system. The drive motor is mounted on the electro-discharge machine bed, the electrode spindle is connected to the output end of the drive motor, the integrated pulse electromagnet electrode structure is connected to the electrode spindle, the auxiliary pulse electromagnet is located below the integrated pulse electromagnet electrode structure, the controller is connected to the integrated pulse electromagnet electrode structure and the auxiliary pulse electromagnet, the fixture is used to mount a workpiece and the auxiliary pulse electromagnet, the workpiece is located between the integrated pulse electromagnet electrode structure and the auxiliary pulse electromagnet and is spaced a certain distance from each of the integrated pulse electromagnet electrode structure and the auxiliary pulse electromagnet, and the workbench supports the fixture.

[0009] The pulse electromagnet integrated electrode structure is connected to the electrode main shaft. The pulse electromagnet integrated electrode structure includes a metal electrode and a coil. The coil is wound around the metal electrode to realize the integrated design of the magnetic-conductive composite. The cylindrical or conical metal of pure iron in the middle acts as both the metal base electrode and the pulse electromagnet core. The outer layer is wrapped with an enameled wire coil, and the upper and lower parts of the coil are fixed by flanges. The direction of the magnetic field is perpendicular to the electrode surface, maximizing the density of magnetic flux lines and ensuring that the magnetorheological fluid forms a uniform solid-state conductive layer. This structure deeply integrates the intelligent response characteristics of the magnetorheological fluid with EDM through the coordinated control of magnetic field, fluid and discharge, realizing the transition of the electrode from "static loss" to "dynamic self-healing".

[0010] By combining the integrated electrode structure of the pulse electromagnet above the workpiece with the auxiliary pulse electromagnet below, with opposite poles facing each other at the workpiece, a closed magnetic circuit is formed in the workpiece processing area, thereby increasing the magnetic induction intensity and uniformity of the magnetic flux lines in the processing area.

[0011] The magnetorheological fluid circulation system includes a recovery tank, an agitator, and a peristaltic pump, which are connected in series through a circulation pipeline. One end of the circulation pipeline is connected to the recovery tank, and the other end is connected to a nozzle. The recovery tank is installed on a workbench, and the nozzle faces the pulse electromagnet integrated electrode structure. The high pressure of the peristaltic pump is used to continuously supply the magnetorheological fluid to the processing area through the nozzle. The recovery tank recovers the discharged magnetorheological fluid into the agitator. The agitator temporarily stores and keeps the magnetorheological fluid evenly suspended to prevent agglomeration and deposition.

[0012] Magnetorheological fluid is continuously supplied to the processing area through a nozzle, generating a pulsed magnetic field on the electrode surface, causing the magnetorheological fluid to form chains along the direction of the magnetic field, rapidly solidifying to form a conductive adhesion layer covering the electrode surface, dynamically compensating for the electrode loss caused by discharge machining. During the intermittent stage of the magnetic field, the magnetorheological fluid restores its liquid properties, and through directional flow, the efficient discharge of the erosion products, active cooling of the processing area, and micro-abrasive-assisted surface finishing are simultaneously achieved.

[0013] Furthermore, the electrode spindle drives the pulse electromagnet integrated electrode structure to move and feed, and the workbench drives the fixture, auxiliary pulse electromagnet and workpiece to move synchronously.

[0014] Furthermore, the metal electrode is an iron electrode, which is made into a cylindrical or conical shape.

[0015] The second aspect of the present invention is to provide a magnetorheological fluid dynamic compensation electrospark machining, the steps of which are as follows:

[0016] S1: First, install the pulse electromagnet integrated electrode structure at the end of the electrode spindle. Then fix the workpiece on the fixture. Place the auxiliary pulse electromagnet under the workpiece and ensure that its spatial position matches the magnetorheological fluid supply pipeline and the pulse electromagnet integrated electrode structure. Connect the magnetorheological fluid circulation system to the processing area and configure the peristaltic pump, stirrer and magnetorheological fluid circulation pipeline.

[0017] S2: Based on the workpiece material and processing target (micropores, narrow grooves, etc.), the initial magnetic field intensity, pulse frequency, and pulse width and pulse interval are preset on the controller. The magnetorheological fluid supply rate is set through the peristaltic pump, and the discharge parameters (pulse width, current, voltage, etc.) are set on the EDM machine control panel.

[0018] S3: Turn on the agitator and peristaltic pump of the magnetorheological fluid circulation system, and continuously supply magnetorheological fluid to the processing area through the nozzle, so that the magnetorheological fluid evenly covers the surface of the substrate electrode, and continuously supply it to the processing area through the nozzle and the agitator to ensure that the particles are evenly suspended;

[0019] S4: The pulse electromagnet integrated electrode structure and the auxiliary pulse electromagnet coil are energized through the controller, and an alternating pulse magnetic field is generated in the processing area between the pulse electromagnet integrated electrode structure and the auxiliary pulse electromagnet. When the positive magnetic field acts, the magnetorheological fluid quickly forms a chain along the direction of the magnetic field in a very short time, quickly solidifies, and forms a conductive adhesion layer; the movement of the electrode spindle and the worktable is controlled to maintain the initial gap between the magnetorheological fluid adhesion layer and the workpiece surface, the electrode and the workpiece are aligned, and the discharge power supply is started; instantaneous demagnetization is achieved by changing the direction and intensity of the pulse magnetic field. At this time, the fluidity of the magnetorheological fluid in the processing area is enhanced, the old magnetorheological fluid will flow down from the electrode, and new magnetorheological fluid will be replenished to dynamically compensate for the fluid electrode loss caused by discharge, effectively maintaining a stable discharge gap, and the magnetorheological fluid realizes efficient discharge of erosion products, active cooling of the processing area, and micro-abrasive assisted surface finishing through directional flow. The above process is repeated continuously to achieve continuous discharge machining;

[0020] S5: The magnetorheological fluid after discharge is recovered through a recovery tank, completing the processing process.

[0021] Unlike traditional electrode configurations, this invention replaces rigid metal electrodes with magnetorheological fluid (MRF). By controlling the solid-liquid phase transition through a pulsed magnetic field, this method creates a "dynamic electrode" EDM mode. The conductive layer is dynamically generated by the magnetic field. Within the alternating pulsed magnetic field, the MRF flows and circulates to replenish and renew the iron powder distribution, compensating for localized defects in the conductive layer caused by EDM erosion. This ensures machining stability and avoids the loss of precision associated with traditional electrode wear.

[0022] Furthermore, the thickness of the conductive layer can be controlled by coordinating the intensity of the pulsed magnetic field with the discharge parameters (e.g., magnetic field frequency and duty cycle);

[0023] Furthermore, the magnetorheological fluid is composed of 45% carbonyl iron powder, 3% oleic acid, 50% silicone oil-based fluid, and 2% nano-SiO2 by volume. During the discharge process, the silicone oil-based fluid acts as the working fluid, and a small amount of unmagnetized hydroxyl iron powder is distributed in it, which reduces the anti-puncture ability of the working fluid, optimizes the discharge process, and thus improves the processing surface quality.

[0024] Beneficial effects of the present invention:

[0025] 1. This invention adopts integrated timing control of multiple processes of discharge-grinding-chip removal, integrating electric spark erosion, micro-abrasive mechanical grinding and fluid flushing (chip removal and cooling) into the same processing cycle. It breaks through the limitation of the single energy effect of traditional electric spark. Micron-sized hydroxy iron powder in magnetorheological fluid is used to perform in-situ finishing of the workpiece surface during the chip removal stage, significantly reducing surface roughness. At the same time, micro-grinding can remove the recast layer and microcracks generated by discharge, thereby improving the fatigue life of the workpiece.

[0026] 2. The present invention dynamically generates "quasi-solid-state electrodes" through magnetorheological fluid. During the processing, local iron powder ablation can be replenished and updated in real time through circulation, without the need to stop the machine to replace or compensate the electrode, avoiding the problem of gradual decline in processing accuracy due to electrode loss in traditional electrospark machining; by utilizing magnetic field distribution regulation, the conductive layer can be dynamically formed according to the surface contour of the workpiece, without the need to customize complex-shaped electrodes, significantly reducing processing preparation costs; through the mechanical grinding effect of micron-sized abrasive particles in the magnetorheological fluid during chip removal and unmagnetized stages, the surface roughness can be reduced, reducing the need for subsequent polishing processes; the continuous cooling effect of liquid magnetorheological fluid reduces the depth of the heat-affected zone of the workpiece, and at the same time, micro-grinding can remove the recast layer and microcracks generated by discharge, thereby improving the fatigue life of the workpiece; the magnetorheological fluid is recovered to the agitator through a recovery tank, improving utilization rate, reducing waste emissions and processing costs.

[0027] 3. The present invention uses pulsed magnetic field control to make the magnetorheological fluid form a solid-state conductive structure, establishes a controllable discharge gap during the discharge phase, and uses the breakdown of a silicone oil-based carrier medium to achieve non-contact discharge machining; during the magnetic field intermittent phase, the magnetorheological fluid restores its liquid properties, and through directional flow, it simultaneously achieves efficient discharge of erosion products, active cooling of the machining area, and micro-abrasive-assisted surface finishing. This method combines the coordinated control of magnetic field intensity and pulse timing to achieve dynamic reconstruction and compensation of the conductive structure, effectively solving the problem of electrode loss compensation. At the same time, the micro-cutting effect of ferromagnetic particles significantly improves the quality of the machined surface. Compared with traditional EDM technology, it has significant advantages such as low electrode loss, stable discharge gap, and low surface roughness. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] Figure 1 Schematic diagram of the structure of the system of the present invention;

[0029] Figure 2 Flow chart of the method of the present invention;

[0030] Figure 3 This is a schematic diagram of the processing principle of the present invention;

[0031] Among them: 1. workbench; 2. fixture; 3. auxiliary pulse electromagnet; 4. workpiece; 5. pulse electromagnet integrated electrode structure; 6. electrode spindle; 7. drive motor; 8. recovery tank; 9. circulation pipeline; 10. peristaltic pump; 11. stirrer; 12. EDM machine bed; 13. controller; 14. magnetorheological fluid adhesion layer; a. hydroxy iron powder; b. oleic acid; c. silicone oil base liquid; d. nano-SiO2. DETAILED DESCRIPTION

[0032] Below in conjunction with specific embodiment, the present invention is described in further detail, described is explanation of the present invention rather than limitation.Unless otherwise defined, all technical terms used hereinafter are identical with the meaning generally understood by those skilled in the art.Technical terms used herein are just for the purpose of describing specific embodiment, are not intended to limit protection scope of the present invention.Unless otherwise specified, the various raw materials, reagent, instrument and equipment etc. used in the present invention all can be purchased by market or can be prepared by existing method.

[0033] like Figure 1 As shown, the magnetorheological fluid dynamic compensation EDM system of this embodiment includes: an EDM machine bed 12, a drive motor 7, an electrode spindle 6, a pulse electromagnet integrated electrode structure 5, an auxiliary pulse electromagnet 3, a controller 13, a fixture 2, a workbench 1 and a magnetorheological fluid circulation system.

[0034] The EDM machine bed 12 has a discharge power supply.

[0035] The driving motor 7 is mounted on the EDM machine bed 12 , and the output end of the driving motor 7 is connected to the electrode spindle 6 , which is connected to the pulse electromagnet integrated electrode structure 5 .

[0036] The pulsed electromagnet integrated electrode structure 5 provides a magnetic field and serves as the metal electrode substrate. It comprises a metal electrode and a coil wound around the metal electrode, achieving an integrated magnetic-conductive composite design. A cylindrical or conical metal core of pure iron serves as both the metal substrate electrode and the pulsed electromagnet core. The outer layer is wrapped with an enameled wire coil, secured above and below by flanges. The magnetic field is oriented perpendicular to the electrode surface, maximizing the magnetic flux density and ensuring the formation of a uniform, quasi-solid conductive layer within the magnetorheological fluid. This structure, through synergistic magnetic field-fluid-discharge control, seamlessly integrates the intelligent response characteristics of magnetorheological fluid with electrospark machining (EDM), achieving a transition from static loss to dynamic self-healing. Preferably, the metal core (electrode) is precision-machined from DT4C industrial pure iron, resulting in low remanence and high saturation magnetization. Its cylindrical or conical design optimizes the magnetic field gradient distribution. This structure, combined with the laminated winding process of the electromagnetic coil, produces a stable and uniform axial magnetic field.

[0037] The auxiliary pulse electromagnet 3 is used to increase the magnetic field strength and uniformity. It is located below the pulse electromagnet integrated electrode structure 5. The pulse electromagnet integrated electrode structure 5 above the workpiece 4 is combined with the auxiliary pulse electromagnet 3 below, and the opposite poles are opposite at the workpiece 4. A closed magnetic circuit is formed in the processing area of the workpiece 4, thereby increasing the magnetic induction intensity and uniformity of the magnetic flux lines in the processing area.

[0038] The controller 13 is used to control the pulse magnetic field parameters, connect the pulse electromagnet integrated electrode structure 5 and the auxiliary pulse electromagnet 3; adjust the discharge parameters pulse magnetic field intensity, frequency, pulse width through the controller 13; pulse power supply parameters: peak current, frequency; realize the in-situ regeneration and precise compensation of the magnetorheological fluid adhesion layer 14 through the dynamic magnetic field control strategy: during the continuous processing process, the reverse excitation current is used to perform instantaneous demagnetization treatment on the pulse electromagnet to improve its fluidity; then, a dense conductive layer with uniform thickness is reconstructed through rapid excitation, and the magneto-induced phase change effect is used to drive the iron powder chain to redistribute in three-dimensional space to form a new iron powder compensation layer.

[0039] The fixture 2 is used to mount a workpiece 4 and an auxiliary pulse electromagnet 3. The workpiece 4 is located between the pulse electromagnet integrated electrode structure 5 and the auxiliary pulse electromagnet 3 and is spaced a certain distance from the pulse electromagnet integrated electrode structure 5 and the auxiliary pulse electromagnet 3. The workbench 1 can move horizontally and is used to support the fixture 2.

[0040] The magnetorheological fluid circulation system includes a recovery tank 8, an agitator 11, and a peristaltic pump 10, which are connected in series via a circulation line 9. The circulation line 9 is connected to the recovery tank 8 at one end and to a nozzle at the other end. The recovery tank 8 is mounted on a workbench 1, and the nozzle faces the pulse electromagnet integrated electrode structure 5. The high pressure of the peristaltic pump 10 continuously supplies the magnetorheological fluid through the nozzle to the processing area. The recovery tank 8 recovers the discharged magnetorheological fluid into the agitator 11, which temporarily stores and maintains the magnetorheological fluid in a uniform suspension to prevent agglomeration and sedimentation. The agitator 11 continuously stirs at a speed of 800-1200 rpm for approximately 20 minutes, allowing the nanoparticles to fully adsorb onto the surface of the iron powder to form a stable coating, ultimately obtaining a uniform suspension system with excellent anti-settling properties and rheological stability.

[0041] The magnetorheological fluid dynamic compensation electrode EDM method based on pulse magnetic field control in this embodiment is as follows: Figure 2 The following steps are shown:

[0042] S1: Install the workpiece. First, install the pulse electromagnet integrated electrode structure 5 on the end of the electrode spindle 6. Then fix the workpiece 4 on the fixture 2. Place the auxiliary pulse electromagnet 3 under the workpiece 4 and ensure that it matches the spatial position of the magnetorheological fluid supply pipeline and the processing area. Connect the magnetorheological fluid circulation system to the processing area and configure the peristaltic pump 10, stirrer 11 and magnetorheological fluid circulation pipeline 9.

[0043] S2: Setting the electromagnet parameters and discharge parameters. According to the material of the workpiece 4 and the processing target (micropores, narrow grooves, etc.), the initial magnetic field strength, pulse frequency, magnetorheological fluid supply rate and discharge parameters (pulse width, current, voltage, etc.) are preset.

[0044] S3: Start the magnetorheological fluid circulation system, turn on the magnetorheological fluid circulation system, make the magnetorheological fluid evenly cover the surface of the substrate electrode, and continuously supply it to the processing area through the nozzle, and through the stirrer 11 to ensure that the particles are evenly suspended;

[0045] S4: The controller energizes the pulse electromagnet integrated electrode structure 5 and the auxiliary pulse electromagnet 3 coils to generate a uniform alternating pulse magnetic field between the pulse electromagnet integrated electrode structure 5 and the auxiliary pulse electromagnet 3. When the positive magnetic field acts, the magnetorheological fluid quickly solidifies to form a conductive adhesion layer; the electrode spindle 6 and the worktable 1 are controlled to move so that the magnetorheological fluid adhesion layer 14 maintains an initial gap with the surface of the workpiece 4, the electrode and the workpiece 4 are aligned, and the discharge power supply of the EDM machine is started to start discharge; after a period of time, the direction of the magnetic field changes to achieve instantaneous demagnetization. At this time, the fluidity of the magnetorheological fluid in the processing area is enhanced, the old magnetorheological fluid will flow down from the electrode, and new magnetorheological fluid will be replenished to dynamically compensate for the fluid electrode loss caused by discharge, effectively maintaining a stable discharge gap, and the magnetorheological fluid achieves efficient discharge of erosion products, active cooling of the processing area, and micro-abrasive assisted surface finishing through directional flow. The above process is repeated continuously to achieve continuous discharge machining;

[0046] S5: The magnetorheological fluid after discharge is recovered through a recovery tank, completing the processing process.

[0047] In this embodiment, the magnetorheological fluid comprises carbonyl iron powder (particle size 5 μm, volume fraction 45%), oleic acid (volume fraction 3%), 50% by volume of high-temperature resistant silicone oil-based liquid, and nano-SiO2 (volume fraction 2%), which is stirred by a stirrer for about 20 minutes to form a uniform suspension.

[0048] like Figure 3 As shown in the figure, after applying a magnetic field, the magnetic particles form a chain structure and exhibit solid-state properties, forming a dense conductive layer of magnetorheological fluid with uniform thickness at the bottom of the electrode, which participates in the discharge as an electrode; during the discharge process, the silicone oil-based liquid acts as the working fluid, and a small amount of unmagnetized hydroxyl iron powder is distributed in it, which reduces the anti-puncture ability of the working fluid, optimizes the discharge process and thus improves the processing surface quality; in the magnetic field reversal stage, the magnetorheological fluid restores its liquid properties, and through directional flow, it simultaneously realizes the efficient discharge of the erosion products, active cooling of the processing area, and micro-abrasive-assisted surface finishing.

[0049] The above embodiments are preferred implementations of the present invention, but the implementation of the present invention is not limited to the above embodiments. Any other changes, modifications, substitutions, combinations, and simplifications that do not deviate from the spirit and principles of the present invention should be considered as equivalent replacement methods and are included in the scope of protection of the present invention.

Claims

1. A magnetorheological fluid dynamic compensation electrospark machining system, characterized in that: include: An EDM machine bed (12) having a discharge power supply; A drive motor (7) is mounted on the EDM machine bed (12); An electrode main shaft (6) connected to the output end of the drive motor (7); A pulse electromagnet integrated electrode structure (5) is connected to the electrode main shaft (6), the pulse electromagnet integrated electrode structure (5) comprising a metal electrode and a coil, the coil being wound around the metal electrode; An auxiliary pulse electromagnet (3) located below the pulse electromagnet integrated electrode structure (5); A controller (13) connected to and controlling the pulse electromagnet integrated electrode structure (5) and the auxiliary pulse electromagnet (3); A fixture (2) is used to install a workpiece (4) and an auxiliary pulse electromagnet (3), wherein the workpiece (4) is located between the pulse electromagnet integrated electrode structure (5) and the auxiliary pulse electromagnet (3) and is spaced a certain distance from the pulse electromagnet integrated electrode structure (5) and the auxiliary pulse electromagnet (3); A workbench (1) supporting the fixture (2); A magnetorheological fluid circulation system comprises a recovery tank (8), an agitator (11), and a peristaltic pump (10) which are sequentially connected in series via a circulation pipeline (9), wherein one end of the circulation pipeline (9) is connected to the recovery tank (8) and the other end is connected to a nozzle, wherein the recovery tank (8) is mounted on a workbench (1), and the nozzle faces a pulse electromagnet integrated electrode structure (5); Magnetorheological fluid is continuously supplied to the processing area through a nozzle, generating a pulsed magnetic field on the electrode surface, causing the magnetorheological fluid to form chains along the direction of the magnetic field and quickly solidify to form a conductive adhesion layer covering the electrode surface, dynamically compensating for the electrode loss caused by discharge machining. During the intermittent stage of the magnetic field, the magnetorheological fluid restores its liquid properties, and through directional flow, efficient discharge of erosion products, active cooling of the processing area, and micro-abrasive-assisted surface finishing are simultaneously achieved. The magnetorheological fluid is composed of 45% carbonyl iron powder, 3% oleic acid, 50% silicone oil-based liquid, and 2% nano-SiO2 by volume. The magnetorheological fluid replaces the rigid metal electrode, and the conductive layer is dynamically reconstructed through the magnetic field to eliminate the problem of electrode loss.

2. The magnetorheological fluid dynamic compensation EDM system according to claim 1, characterized in that: The electrode spindle (6) drives the pulse electromagnet integrated electrode structure (5) to move and feed, and the workbench (1) drives the fixture (2), the auxiliary pulse electromagnet (3) and the workpiece (4) to move synchronously.

3. The magnetorheological fluid dynamic compensation EDM system according to claim 1, characterized in that: The metal electrode is an iron electrode and is made into a cylindrical or conical shape.

4. The processing method of the processing system according to any one of claims 1 to 3, characterized in that: Here are the steps: S1: turning on the stirrer (11) and the peristaltic pump (10) of the magnetorheological fluid circulation system, and continuously supplying magnetorheological fluid to the processing area through the nozzle, so that the magnetorheological fluid evenly covers the surface of the electrode structure; S2: The pulse electromagnet integrated electrode structure (5) and the auxiliary pulse electromagnet (3) coils are energized through the controller (13), and a uniform alternating pulse magnetic field is generated between the pulse electromagnet integrated electrode structure (5) and the auxiliary pulse electromagnet (3). When the positive magnetic field acts, the magnetorheological fluid is rapidly solidified to form a conductive adhesion layer. The electrode spindle (6) and the worktable (1) are controlled to move so that the magnetorheological fluid adhesion layer (14) maintains an initial gap with the surface of the workpiece (4). The electrode and the workpiece (4) are aligned, and the discharge power supply is started to start discharging. After a period of time, the direction of the magnetic field changes to achieve instant demagnetization. At this time, the fluidity of the magnetorheological fluid in the processing area is enhanced, and the old magnetorheological fluid will flow down from the electrode. At the same time, new magnetorheological fluid is replenished to dynamically compensate for the fluid electrode loss caused by discharge and maintain a stable discharge gap. The magnetorheological fluid achieves efficient discharge of erosion products, active cooling of the processing area, and micro-abrasive assisted surface finishing through directional flow. The above steps are repeated continuously to achieve continuous discharge machining. S3: The magnetorheological fluid after discharge is recovered through the recovery tank (8), completing the processing process.

5. The processing method according to claim 4, characterized in that: Before machining, the initial magnetic field intensity, pulse frequency, magnetorheological fluid supply rate and discharge parameters are preset according to the workpiece material and machining target.

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