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微细电解线切割是一种新型的微细加工技术,适合高精度金属窄缝、窄槽等微细结构的加工,由于加工间隙内电解产物排出困难,容易影响加工精度。为了提高产物排出效率,提出线电极微幅往复走丝促进加工间隙内电解产物排出的方法,改善了加工稳定性,提高了加工精度和加工效率。建立了间隙内电解产物排出效率对加工精度、加工速度影响的数学模型,分析了线电极走丝速度和走丝幅值对间隙内电解产物排出和电解液更新的影响。通过试验研究了线电极的走丝速度和走丝幅值对加工精度和加工效率的影响规律,采用优化参数在厚度为80μm的钴基弹性合金上进行微槽结构加工,底面粗糙度约为0.45μm,倒角半径小于8μm。结果表明线电极轴向微幅往复走丝可以有效地提高加工质量和加工效率。
Micro-electrolysis wire cutting is a new type of micro-machining technology, suitable for precision metal narrow slit, narrow groove and other fine structure of the processing, as electrolysis products within the gap discharge difficult to easily affect the machining accuracy. In order to improve the discharge efficiency of the product, the paper proposed a method that the wire electrode moves back and forth slightly to promote the discharge of the electrolysis products in the machining gap, which improves the processing stability and improves the processing precision and processing efficiency. The mathematical model of the effect of the discharge efficiency of electrolysis products on the machining accuracy and processing speed was set up. The influence of the wire speed and the wire width on the discharge of the electrolysis products and the electrolyte renewal in the gap was analyzed. The influence of the wire speed and the wire width on the machining accuracy and machining efficiency was studied through experiments. The micro-groove structure was machined on the cobalt-based elastic alloy with the thickness of 80μm by using optimized parameters. The roughness of the bottom surface was about 0.45 μm, chamfer radius less than 8μm. The results show that the axial reciprocating wire electrode can effectively improve the processing quality and processing efficiency.