电火花加工技术应用在模具制造中电加工的应用(Application of EDM Technology in die manufacturing).doc
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1、电火花加工技术应用在模具制造中电加工的应用(Application of EDM Technology in die manufacturing)Application of EDM Technology in die manufacturingRelated topics: Die technology, literature time: 2010-08-25 10:02In todays world, with each passing day, all walks of life are developing rapidly. Among them, the development of
2、 materials science and the development of the machinery industry are particularly rapid, and the links between the two industries are becoming more and more close. Among them, a very specific performance is with the development of material science, in order to meet the needs of some special circumst
3、ances, a large number of high strength, high hardness, high toughness, high brittleness, high temperature and other special properties of die materials have been produced, which has brought many difficulties and problems to the traditional. With the traditional processing methods to meet the require
4、ments. As for the workpiece with complex structures, such as complex cavity die hole model by cutting the traditional methods it is often difficult to achieve, so people in the production of some new methods, and some have been widely used. Among them, EDM is one of them. It is widely used in die an
5、d mould manufacturing industry.First, the mechanism and characteristics of EDMElectrical discharge machining (EDM) is a method of machining workpieces in a certain medium by means of electrical erosion between the electrodes of the tool and the discharge of the electrodes between the workpieces. The
6、 principle of EDM is shown in the following figure.Automatic feed adjustment device for the 3 hydraulic cylinder and piston to keep discharge between the tool and the workpiece in a small gap, when the pulse voltage applied between the poles, then at that time under the conditions of relative to a m
7、inimum gap or the insulation strength of the weakest breakdown medium in the local production of spark discharge, the tool and the instantaneous high temperature the workpiece surface partial melting, vaporization and even electric erosion off a small part of the metal, each form a small pits. The p
8、ulse after discharge, through the pulse interval, so that the working fluid recovery after insulation, second pulse voltage and added to the poles, and at the time the distance between the relatively recent or weakest at the breakdown discharge and electrical insulation, corrosion of a small pit. Th
9、e entire machined surface will consist of numerous small pits. This discharge cycle repeats thousands of times per second to tens of thousands of times, causing the surface of the workpiece to form many, very small pits called electrical erosion. As the tool electrode continues to feed, the outline
10、size of the tool electrode is precisely copied on the workpiece to achieve the purpose of forming.Electrical discharge machining (EDM) can process various materials with high melting point, high hardness, high strength, high purity and high toughness, but its machining mechanism is different from th
11、at of the cutting method, and has the following characteristics:1, pulse discharge energy density is high, easy to process, with ordinary mechanical processing method difficult to process or unable to process special materials and complex shape workpiece. Not affected by material hardness, not affec
12、ted by heat treatment condition. 2, the duration of pulse discharge is very short, the heat conduction in discharge is small and the range of heating is small. 3, when machining, tool electrode and workpiece materials do not contact, the smallest of the micro force between the two. Tool electrode ma
13、terials do not need to be harder than workpiece materials, so tool electrodes are easy to manufacture. 4, we can reform the structure of the workpiece, simplify the processing technology, improve the service life of the workpiece and reduce the labor intensity of the workers.Two, the main factors af
14、fecting the quality of die EDMThe processing quality of the die mainly includes machining accuracy and the quality of the etched surface. Because of the EDM process input and output parameters more and more complex, the influence of die machining precision process factors involved in organic bed its
15、elf manufacturing precision, workpiece clamping precision, electrode manufacture and clamping precision, electrode loss, discharge gap, machining inclination etc., the electrode loss and discharge gap greater impact.1, the influence of electrode loss on machining accuracyIn the mold EDM process, pul
16、se discharge will make the tool electrode by galvanic corrosion and loss, thus to understand and grasp the law of electrode loss and take various measures, to minimize the loss of tool electrode,To ensure that the mold has higher machining accuracy. EDM, different parts of the tool electrode loss si
17、tuation is different, the electric field strength usually sharp corners, edges and projections of the high, easy to form the tip discharge, so the loss ratio of flat parts to be fast, uneven loss will inevitably lead to a decline in accuracy. The electrode loss is also affected by the thermal and ph
18、ysical constants of the electrode material. The higher the melting point, boiling point, specific heat capacity, melting and gasification latent heat of electrode materials, the greater the thermal conductivity, the better the corrosion resistance, the better the heat transfer ability, and thus the
19、electrode loss can be reduced.2, the impact of discharge gap on the machining accuracyEDM die, pulse discharge need to maintain a discharge gap between the tool electrode and the workpiece, and the processed workpiece hole size and electrode size compared to the contour along the processing by a dis
20、charge gap. The discharge gap mainly determines the machining stability, and the increase of the pulse gap time can improve the machining stability. Increasing peak current will increase productivity, but the electrode loss will increase.When the surface layer is deepened, the roughness will become
21、larger. To make the discharge gap remained stable, must make the electrical parameters of pulse power supply remains stable, moreover also should make the machine precision and rigidity are stable, while paying special attention to the influence of the two products caused by spark erosion on the dis
22、charge gap.3, influence on the machined surface roughnessThe roughness parameter Ra of the etched surface increases with the increase of pulse width and current peak. Under certain processing conditions, the increase of pulse width and current peak will increase the energy of single pulse and increa
23、se the cross section size of erosion pits, so the surface roughness mainly depends on the size of single pulse energy. To reduce the value of the surface roughness Ra, the energy of a single pulse must be reduced.4. The influence of surface change layer on the surface quality of moldThe surface of t
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