CN114473091B - A horizontal electrolytic electric discharge machining device and method - Google Patents
A horizontal electrolytic electric discharge machining device and method Download PDFInfo
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- 238000003754 machining Methods 0.000 title claims abstract description 27
- 239000003792 electrolyte Substances 0.000 claims abstract description 20
- 238000009760 electrical discharge machining Methods 0.000 claims description 20
- 230000005540 biological transmission Effects 0.000 claims description 5
- 238000003487 electrochemical reaction Methods 0.000 claims description 3
- 239000011152 fibreglass Substances 0.000 claims description 3
- -1 polytetrafluoroethylene Polymers 0.000 claims description 3
- 229920001343 polytetrafluoroethylene Polymers 0.000 claims description 3
- 239000004810 polytetrafluoroethylene Substances 0.000 claims description 3
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- 238000000576 coating method Methods 0.000 claims description 2
- 238000007789 sealing Methods 0.000 claims description 2
- 230000033001 locomotion Effects 0.000 abstract description 7
- 238000005868 electrolysis reaction Methods 0.000 abstract description 5
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- 230000003628 erosive effect Effects 0.000 abstract description 4
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- 238000010892 electric spark Methods 0.000 abstract 1
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23H—WORKING OF METAL BY THE ACTION OF A HIGH CONCENTRATION OF ELECTRIC CURRENT ON A WORKPIECE USING AN ELECTRODE WHICH TAKES THE PLACE OF A TOOL; SUCH WORKING COMBINED WITH OTHER FORMS OF WORKING OF METAL
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- B23H5/02—Electrical discharge machining combined with electrochemical machining
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Abstract
本发明公开了一种水平式电解电火花加工装置及方法,加工时,工具电极和工件同时浸没在电解液中,工具电极水平置于工件下方,工件由进给调节系统控制进给,工具电极由电极水平旋转系统控制旋转。该装置改变了传统加工过程中工具电极和工件之间的相对位置,通过工件的进给运动来实现工件的加工。本申请采用工件倒置且工具电极水平放置的布局形式,形成“线”或“面”式的加工,弥补常规电解电火花加工装置单一纵向“点”式加工的不足,大幅度提高槽的加工质量,蚀除产物受重力作用能够快速排出极间,增强了加工过程中电解质流动能力,能够形成稳定气膜,从而提高加工效率。
The invention discloses a horizontal electrolysis electric spark processing device and method. During processing, a tool electrode and a workpiece are immersed in an electrolyte solution at the same time, the tool electrode is horizontally placed under the workpiece, and the feed of the workpiece is controlled by a feed adjustment system. The tool electrode The rotation is controlled by the electrode horizontal rotation system. The device changes the relative position between the tool electrode and the workpiece in the traditional machining process, and realizes the machining of the workpiece through the feed movement of the workpiece. This application adopts the layout form in which the workpiece is inverted and the tool electrodes are placed horizontally to form "line" or "surface" processing, which makes up for the lack of single longitudinal "point" processing of conventional electrolytic EDM devices, and greatly improves the processing quality of grooves , The erosion products can be quickly discharged between the electrodes under the action of gravity, which enhances the flow capacity of the electrolyte during processing, and can form a stable gas film, thereby improving processing efficiency.
Description
技术领域technical field
本发明属于特种加工技术领域,尤其涉及一种水平式电解电火花加工装置及方法。The invention belongs to the technical field of special processing, and in particular relates to a horizontal electrolysis electric discharge processing device and method.
背景技术Background technique
近年来,随着现代工业的高速发展,新型难加工材料的不断发现,微型化和精密化成为现在先进制造业发展的一个重要方向,对复杂微小零件的加工要求也越来越高。同时,随着微机电系统、微流体系统、航空航天等领域的蓬勃发展,耐热玻璃、陶瓷等具有耐高温、耐腐蚀、强度高等性能的非导电硬脆材料的应用也越来越广泛。然而,绝大部分硬脆材料,由于加工难度大,加工精度、表面质量和损伤层深度都将会对器件的性能产生影响,所以难以用传统的微细机械切削方法和常规的电火花加工技术对其加工。电解加工是一种基于阳极电化学溶解原理去除金属材料的制造技术,具有表面质量好、不受材料限制、工具无损耗等优点,加工过程中不存在变形层和残余应力等问题。In recent years, with the rapid development of modern industry and the continuous discovery of new difficult-to-machine materials, miniaturization and precision have become an important direction for the development of advanced manufacturing industries, and the processing requirements for complex and tiny parts are also getting higher and higher. At the same time, with the vigorous development of microelectromechanical systems, microfluidic systems, aerospace and other fields, heat-resistant glass, ceramics and other non-conductive hard and brittle materials with high temperature resistance, corrosion resistance, and high strength are more and more widely used. However, most of the hard and brittle materials are difficult to process, and the processing accuracy, surface quality and depth of the damaged layer will all have an impact on the performance of the device, so it is difficult to use traditional micro-machining methods and conventional EDM techniques. its processing. Electrolytic machining is a manufacturing technology based on the principle of anodic electrochemical dissolution to remove metal materials. It has the advantages of good surface quality, not limited by materials, and no loss of tools. There are no problems such as deformed layers and residual stress during processing.
电解电火花的加工过程大致为:阴极和阳极电解产生气泡,气泡经过聚集产生气膜,并包围在工件表面,气膜对电极产生绝缘作用,在工具电极和电解质溶液之间形成电势差,工具电极在气膜处产生电火花放电,工件材料就会在不断放电产生的热量作用下被蚀除。由上述加工过程可知,气膜是产生电火花效应的必要条件,气膜的厚度、形成速度、稳定性等都对加工过程有着非常重要的影响。但由于目前常采用的电解液的表面张力、粘度、密度等都比较小,因此,电解过程所产生的气泡会在浮力的作用下溢出电解液表面,使得只有小部分气泡可以参与气层的形成,从而使得气层的形成占据了比较长的时间,而这会大大缩短有效的放电时间,降低加工效率。The processing process of electrolytic spark is roughly as follows: the cathode and anode electrolysis generate bubbles, the bubbles gather to form a gas film, and surround the surface of the workpiece, the gas film insulates the electrode, and forms a potential difference between the tool electrode and the electrolyte solution, and the tool electrode Spark discharge is generated at the gas film, and the workpiece material will be eroded under the action of heat generated by continuous discharge. It can be seen from the above processing that the air film is a necessary condition for generating the spark effect, and the thickness, formation speed, and stability of the air film all have a very important influence on the processing process. However, due to the relatively small surface tension, viscosity, and density of the commonly used electrolyte, the bubbles generated in the electrolysis process will overflow the surface of the electrolyte under the action of buoyancy, so that only a small part of the bubbles can participate in the formation of the gas layer. , so that the formation of the gas layer takes a relatively long time, which will greatly shorten the effective discharge time and reduce the processing efficiency.
中国专利CN102528187A公开了一种倒置式电化学放电加工方法及装置,该申请提供一种特种加工领域的倒置电化学放电加工方法,具体是将工具电极安装在工件的下方,工具电极通过电极夹具固定在工作槽的底面并且浸没在电解质溶液中,工件与机床的进给装置相连接,通过工件的进给来实现加工过程中的进给运动。还提供相应的装置,通过改变工具电极和工件之间的相对位置,使加工过程中产生的加工屑在重力的作用下能够比较容易地排出,这就使得加工过程中加工孔内电解质的流动能力得到了增强,而且由于采用倒置布局,电解反应产生的气泡会富集在加工工件下方电极端部的周围,形成稳定的气膜,从而有效增加了电化学放电加工过程的稳定性并保证了加工深度。但是,该技术主要解决的是孔类或微槽类零件的微细电火花加工问题,更多的是实现了高效“点”式加工,运用在槽加工或缝加工过程中时,加工范围有限,存在明显地效率慢的问题。Chinese patent CN102528187A discloses an inverted electrochemical discharge machining method and device. This application provides an inverted electrochemical discharge machining method in the field of special processing. Specifically, the tool electrode is installed under the workpiece, and the tool electrode is fixed by the electrode fixture. On the bottom surface of the working tank and immersed in the electrolyte solution, the workpiece is connected with the feeding device of the machine tool, and the feeding motion during the machining process is realized by the feeding of the workpiece. Corresponding devices are also provided. By changing the relative position between the tool electrode and the workpiece, the machining debris generated during the machining process can be discharged relatively easily under the action of gravity, which makes the flow capacity of the electrolyte in the machining hole during the machining process It has been enhanced, and because of the inverted layout, the bubbles generated by the electrolytic reaction will be enriched around the end of the electrode under the workpiece to form a stable gas film, thereby effectively increasing the stability of the electrochemical discharge machining process and ensuring the machining depth. However, this technology mainly solves the problem of micro-EDM of holes or micro-groove parts, and realizes more efficient "point" processing. When it is used in groove processing or seam processing, the processing range is limited. There is an obvious problem of slow efficiency.
发明内容Contents of the invention
本发明的目的在于解决现有技术中的不足,提供一种水平式电解电火花加工装置及方法。加工时,将工具电极水平放置,改变了工具电极和加工工件之间的相对位置,工具电极位于加工工件下方并浸没在电解质溶液之中,能够在较厚工件上进行槽的加工,根据电极选择的不同,也可进行线切割加工,扩大微细电火花加工范围。The object of the present invention is to solve the deficiencies in the prior art, and provide a horizontal electrolytic electric discharge machining device and method. During processing, the tool electrode is placed horizontally, which changes the relative position between the tool electrode and the workpiece. The tool electrode is located under the workpiece and immersed in the electrolyte solution, which can process grooves on thicker workpieces. According to the electrode selection It can also be processed by wire cutting to expand the range of micro EDM.
本发明的技术方案为:一种水平式电解电火花加工装置,包括电解箱、辅助电极、工具电极、电源、工件和进给调节系统,电解箱中盛有电解液,辅助电极与电源的正极相接,工具电极与电源的负极相接,工具电极和工件同时浸没在电解液中,工具电极水平置于工件下方,工件由进给调节系统控制进给,工具电极与电极水平旋转系统相连接并由电极水平旋转系统控制旋转。The technical solution of the present invention is: a horizontal electrolytic EDM device, including an electrolytic box, an auxiliary electrode, a tool electrode, a power supply, a workpiece and a feed adjustment system, the electrolytic box contains electrolyte, the auxiliary electrode and the positive electrode of the power supply Connected, the tool electrode is connected to the negative pole of the power supply, the tool electrode and the workpiece are immersed in the electrolyte at the same time, the tool electrode is placed below the workpiece horizontally, the workpiece is fed by the feed adjustment system, and the tool electrode is connected to the electrode horizontal rotation system And the rotation is controlled by the electrode horizontal rotation system.
进一步地,电极水平旋转系统包括第一伺服电机、旋转主轴和底座,第一伺服电机设在机箱侧壁上,第一伺服电机与旋转主轴间通过传动带传动连接,旋转主轴水平活动连接在机箱底部的轴承座上,在旋转主轴端部设有电极夹头,工具电极通过电极夹头固定在旋转主轴上,在旋转主轴上设有进电块,进电块与电源的负极相连接,进电块与工具电极之间电性连接。Further, the electrode horizontal rotation system includes a first servo motor, a rotating main shaft and a base, the first servo motor is arranged on the side wall of the case, the first servo motor is connected to the rotating main shaft through a transmission belt, and the rotating main shaft is horizontally and movably connected to the bottom of the case On the bearing seat, there is an electrode chuck at the end of the rotating spindle, and the tool electrode is fixed on the rotating spindle through the electrode chuck. There is a power-in block on the rotating shaft. The power-in block is connected to the negative pole of the power supply. The block is electrically connected to the tool electrode.
进一步地,电解液平面与工具电极上表面之间的距离小于2 mm。Further, the distance between the electrolyte plane and the upper surface of the tool electrode is less than 2 mm.
进一步地,在电解箱底部设有电极支撑装置,电极支撑装置包括支撑杆、活动块和丝杆,丝杆水平置于电解箱底部,丝杆两端可转动地连接在电解箱底部两侧设置的轴承块上且其一端穿出电解箱后与第二伺服电机相连,活动块通过其内设置的丝杆螺母活动穿套在丝杆上,支撑杆固定在活动块上,支撑杆端部为锥形且其尖端与工具电极端部相接触。Further, an electrode support device is provided at the bottom of the electrolytic box. The electrode support device includes a support rod, a movable block and a screw rod. The screw rod is placed horizontally at the bottom of the electrolytic box, and the two ends of the screw rod are rotatably connected to the bottom of the electrolytic box. On the bearing block and one end of which passes through the electrolytic box and is connected with the second servo motor, the movable block is movably worn on the screw rod through the screw nut provided in it, the support rod is fixed on the movable block, and the end of the support rod is Conical with its tip in contact with the end of the tool electrode.
进一步地,工具电极为电极丝或者是柱形电极;柱形电极为圆柱体状工具电极时,加工过程中第一伺服电机工作,带动圆柱体状工具电极以0-2500 r/min的速度旋转加工;柱形电极为非圆柱体状电极时,工具电极在加工过程中不旋转。Further, the tool electrode is an electrode wire or a cylindrical electrode; when the cylindrical electrode is a cylindrical tool electrode, the first servo motor works during the processing, driving the cylindrical tool electrode to rotate at a speed of 0-2500 r/min Processing; when the cylindrical electrode is a non-cylindrical electrode, the tool electrode does not rotate during processing.
进一步地,在电极夹头与电解箱的配合面间设有密封件。Further, a seal is provided between the matching surface of the electrode clamp and the electrolytic box.
进一步地,支撑杆由聚四氟乙烯材料制成。Further, the support rod is made of polytetrafluoroethylene.
进一步地,丝杆外层涂有玻璃钢涂层。Further, the outer layer of the screw rod is coated with fiberglass.
上述水平式电解电火花加工装置的工作方法如下:The working method of the above-mentioned horizontal electrolytic EDM device is as follows:
a.安装在旋转主轴上的工具电极处于待加工工件下方,工具电极长度<30 mm时,支撑杆尖端与工具电极不接触,工具电极长度≥30 mm时,启动第二伺服电机带动支撑杆以1-10 mm/s的速度水平移动直至支撑杆的尖端与工具电极自由端相接触支撑;a. The tool electrode installed on the rotating spindle is under the workpiece to be processed. When the length of the tool electrode is less than 30 mm, the tip of the support rod does not touch the tool electrode. When the length of the tool electrode is ≥ 30 mm, start the second servo motor to drive the support rod to Move horizontally at a speed of 1-10 mm/s until the tip of the support rod is in contact with the free end of the tool electrode;
b. 工件在机床自带的进给调节系统的带动下以一定速度做进给运动,与此同时启动电源,在电源控制下,浸入电解液中的工具电极表面发生电化学反应,在工具电极表面产生气泡,气泡经过聚集产生气膜,进而在工具电极表面和气泡外表面形成电势差,击穿电极表面的气泡发生放电,从而对非导电的工件进行电火花蚀除;b. Driven by the feed adjustment system of the machine tool, the workpiece is fed at a certain speed. At the same time, the power is turned on. Under the control of the power supply, an electrochemical reaction occurs on the surface of the tool electrode immersed in the electrolyte. Bubbles are generated on the surface, and the bubbles are gathered to form a gas film, and then a potential difference is formed on the surface of the tool electrode and the outer surface of the bubbles, and the bubbles that penetrate the surface of the electrode are discharged, thereby performing spark erosion on the non-conductive workpiece;
c. 进给调节系统带动工件继续以稳定的速度做进给运动,直到完成对工件的加工。c. The feed adjustment system drives the workpiece to continue to feed at a stable speed until the workpiece is processed.
本申请的有益效果为:The beneficial effect of this application is:
1.本申请中工具电极采用水平方式布局,相较于常规采用单一纵向“点”加工方式进行微细电火花放电加工的装置而言,可进行“线”或“面”的加工以及较厚非导电材料的加工,根据电极的选择不同,也可进行线切割的加工,大幅度提高深径比,扩大加工范围,提高加工效率;1. In this application, the tool electrode is laid out in a horizontal manner. Compared with the conventional device that uses a single longitudinal "point" processing method for micro-EDM, it can perform "line" or "surface" processing and thicker non-woven fabrics. The processing of conductive materials can also be processed by wire cutting according to the selection of electrodes, which can greatly improve the depth-to-diameter ratio, expand the processing range, and improve processing efficiency;
2. 水平布局方式进行加工时,电解反应产生的气泡会富集在待加工工件下方的工具电极的周围,易于在电极表面形成稳定性的气膜,增大放电面积,从而保证了加工的顺利进行;2. When processing in a horizontal layout, the bubbles generated by the electrolytic reaction will be concentrated around the tool electrode under the workpiece to be processed, which is easy to form a stable gas film on the surface of the electrode and increase the discharge area, thus ensuring smooth processing conduct;
3. 采用水平布局,加工过程中产生的放电蚀除物在重力的作用下能够比较容易地排出,对电蚀屑的顺利排出起到更积极作用,这就使得电解质溶液的流动性增强,减少了短路和非正常放电现象的发生,放电加工状态更加稳定;3. With the horizontal layout, the discharge erosion generated during the processing can be easily discharged under the action of gravity, which plays a more active role in the smooth discharge of electric erosion debris, which enhances the fluidity of the electrolyte solution and reduces The occurrence of short circuit and abnormal discharge phenomenon is avoided, and the discharge machining state is more stable;
4. 电蚀物的顺利排出,可减少非正常放电的发生,促进了热量的散失,减少了对工具电极的损坏,同时短路和拉弧现象减少,能有效提高加工精度。4. The smooth discharge of electric corrosion can reduce the occurrence of abnormal discharge, promote heat loss, reduce damage to tool electrodes, and reduce short circuit and arcing, which can effectively improve machining accuracy.
附图说明Description of drawings
图1是一种水平式电解电火花加工装置的结构示意图;Fig. 1 is a schematic structural view of a horizontal electrolytic spark machining device;
图2是工具电极为长度<30 mm的短圆柱体状电极时的加工示意图;Fig. 2 is a schematic diagram of processing when the tool electrode is a short cylindrical electrode with a length < 30 mm;
图3是工具电极为长度≥30 mm的长圆柱体状电极时的加工示意图;Figure 3 is a schematic diagram of processing when the tool electrode is a long cylindrical electrode with a length ≥ 30 mm;
其中,1-电解箱,2-辅助电极,3-工具电极,4-电源,5-工件,6-进给调节系统,7-电极水平旋转系统,8-电极支撑装置;Among them, 1-electrolytic box, 2-auxiliary electrode, 3-tool electrode, 4-power supply, 5-workpiece, 6-feed adjustment system, 7-electrode horizontal rotation system, 8-electrode support device;
71-第一伺服电机,72-旋转主轴,73-底座,74-机箱,75-轴承座,76-电极夹头,77-进电块,78-密封件;71-first servo motor, 72-rotating main shaft, 73-base, 74-chassis, 75-bearing seat, 76-electrode chuck, 77-power feed block, 78-seal;
81-支撑杆,82-活动块,83-丝杆,84-第二伺服电机。81-support rod, 82-movable block, 83-screw mandrel, 84-the second servo motor.
具体实施方式Detailed ways
以下实施例进一步说明本发明的内容,但不应理解为对本发明的限制。在不背离本发明实质的情况下,对本发明方法、步骤或条件所作的修改和替换,均属于本发明的范围。The following examples further illustrate the content of the present invention, but should not be construed as limiting the present invention. Without departing from the essence of the present invention, the modifications and substitutions made to the methods, steps or conditions of the present invention all belong to the scope of the present invention.
实施例一Embodiment one
为了扩大加工范围,解决电解电火花加工过程中“线”、“面”高效加工的难题,以及实现对较厚非导电材料的加工,本实施例中公开一种水平式电解电火花加工装置。 In order to expand the processing range, solve the problem of high-efficiency processing of "line" and "surface" in the EDM process, and realize the processing of thicker non-conductive materials, a horizontal EDM device is disclosed in this embodiment.
该装置包括电解箱1、辅助电极2、工具电极3、电源4、工件5、进给调节系统6和电极水平旋转系统7;电解箱1中盛有电解液,辅助电极2与电源4的正极相接,工具电极3与电源4的负极相接,工具电极3和工件5同时浸没在电解液中,工具电极3水平置于工件5下方,工件5通过工件夹头连接在进给调节系统上并由进给调节系统控制进给,通过工件的进给来实现加工过程中的进给运动,工具电极3与电极水平旋转系统7相连接。The device includes an electrolysis box 1, an auxiliary electrode 2, a tool electrode 3, a power supply 4, a workpiece 5, a feed adjustment system 6, and an electrode horizontal rotation system 7; connected, the tool electrode 3 is connected to the negative pole of the power supply 4, the tool electrode 3 and the workpiece 5 are immersed in the electrolyte at the same time, the tool electrode 3 is horizontally placed under the workpiece 5, and the workpiece 5 is connected to the feed adjustment system through the workpiece chuck The feed is controlled by the feed adjustment system, and the feed movement in the machining process is realized through the feed of the workpiece. The tool electrode 3 is connected with the electrode horizontal rotation system 7 .
电极水平旋转系统7包括第一伺服电机71、旋转主轴72和底座73,第一伺服电机71设在机箱74侧壁上,第一伺服电机71与旋转主轴72间通过传动带传动的方式连接(以传动带实现的传动连接形式为现有技术中的常见结构,在此不多做赘述),旋转主轴72可转动地水平连接在机箱74底部的轴承座75上,在旋转主轴72端部设有电极夹头76,工具电极3通过电极夹头76固定在旋转主轴72上,在旋转主轴72上设有进电块77,进电块77与电源4的负极相连接,进电块77与工具电极3之间电性连接。The electrode horizontal rotation system 7 includes a first servo motor 71, a rotating main shaft 72 and a base 73. The first servo motor 71 is arranged on the side wall of the cabinet 74, and the first servo motor 71 is connected with the rotating main shaft 72 by means of a transmission belt (with The transmission connection form realized by the transmission belt is a common structure in the prior art, so I won’t go into details here), the rotating main shaft 72 is rotatably connected to the bearing seat 75 at the bottom of the chassis 74, and electrodes are arranged at the end of the rotating main shaft 72 Chuck 76, the tool electrode 3 is fixed on the rotating main shaft 72 through the electrode chuck 76, and the power feeding block 77 is arranged on the rotating main shaft 72, and the power feeding block 77 is connected with the negative pole of the power supply 4, and the power feeding block 77 is connected with the tool electrode 3 are electrically connected.
在电极夹头76与电解箱1的配合面间设有密封件78以增强连接处的密封效果,保证设备能抵御电解液的腐蚀、能够长期稳定运行。A seal 78 is provided between the mating surface of the electrode clamp 76 and the electrolytic box 1 to enhance the sealing effect of the connection, so as to ensure that the equipment can resist the corrosion of the electrolyte and can run stably for a long time.
为满足线、面加工要求,工具电极3可为电极丝或者是柱形电极,柱形电极可选圆柱体状工具电极或非圆柱体状工具电极(包括矩形体状工具电极或其他形状的工具电极,具体形貌不做过多限制),当选择圆柱体状工具电极进行加工时,第一伺服电机71工作,带动圆柱体状工具电极3以0-2500 r/min的速度旋转加工,当选择的柱形电极为非圆柱体状电极时,工具电极3在加工过程中不旋转。In order to meet the requirements of line and surface processing, the tool electrode 3 can be an electrode wire or a cylindrical electrode, and the cylindrical electrode can be a cylindrical tool electrode or a non-cylindrical tool electrode (including a rectangular tool electrode or other shaped tools electrode, the specific shape is not too limited), when the cylindrical tool electrode is selected for processing, the first servo motor 71 works, driving the cylindrical tool electrode 3 to rotate at a speed of 0-2500 r/min for processing, when When the selected cylindrical electrode is a non-cylindrical electrode, the tool electrode 3 does not rotate during processing.
所述电源4为直流电源或脉冲电源,直流电源为可调节直流电源,直流脉冲电源为高电压、脉宽、脉间、峰值电流均独立可调的脉冲电源。The power supply 4 is a DC power supply or a pulse power supply, the DC power supply is an adjustable DC power supply, and the DC pulse power supply is a pulse power supply with independently adjustable high voltage, pulse width, pulse interval and peak current.
电解液选自氢氧化钠溶液、氢氧化钾溶液中的一种或多种,电解液平面与工具电极3上表面之间的距离小于2 mm。The electrolyte is selected from one or more of sodium hydroxide solution and potassium hydroxide solution, and the distance between the electrolyte plane and the upper surface of the tool electrode 3 is less than 2 mm.
对工具电极3进行侧面绝缘,绝缘部分位于工具电极3上靠近电极夹头76的一端,绝缘长度为1-3 mm。The side of the tool electrode 3 is insulated, the insulating part is located on the end of the tool electrode 3 close to the electrode clamp 76, and the insulation length is 1-3 mm.
辅助电极2由化学性质稳定且导电性良好的石墨材料制成。The auxiliary electrode 2 is made of graphite material with stable chemical properties and good conductivity.
当电源4在工具电极3和辅助电极2之间施加电压以后,工具电极3表面产生氢气泡,随着气泡的增多,气泡不断合并,在工具电极3表面形成气膜,由于气膜的绝缘作用使得在工具电极3和电解液之间形成电势差,当施加的电源电压超过临界电压值以后,在工具电极3和电解液之间发生火花放电,放电产生的能量将工件材料蚀除。此时,工件5在进给调节系统的带动下进给,保持工具电极3和工件5相邻端面之间的距离在30 μm以内,直到加工完成。When the power supply 4 applies a voltage between the tool electrode 3 and the auxiliary electrode 2, hydrogen bubbles are generated on the surface of the tool electrode 3. As the bubbles increase, the bubbles continue to merge and form a gas film on the surface of the tool electrode 3. Due to the insulating effect of the gas film A potential difference is formed between the tool electrode 3 and the electrolyte. When the applied power voltage exceeds the critical voltage value, a spark discharge occurs between the tool electrode 3 and the electrolyte, and the energy generated by the discharge will erode the workpiece material. At this time, the workpiece 5 is fed under the drive of the feed adjustment system, and the distance between the tool electrode 3 and the adjacent end surface of the workpiece 5 is kept within 30 μm until the processing is completed.
利用本实施例提供的装置进行水平式电解电火花放电加工过程时,由于采用水平加工方法,加工过程中产生的加工屑在重力的作用下能够比较容易地排出,对电蚀屑的顺利排出起到更积极作用,这就使得加工过程中电解质的流动能力得到了增强,减少了短路和非正常放电现象的发生;且由于采用水平布局,电解反应产生的气泡会富集在待加工工件下方电极的周围,增加了气膜的稳定性,从而有效增加了加工稳定性和加工深度;另外,水平布局能够弥补常规微细电火花放电加工采用单一纵向“点”加工方式的缺陷,可进行“线”或“面”的加工以及较厚非导电材料槽的加工,根据电极的选择不同,也可进行线切割的加工,增加放电加工深度,扩大加工范围,提高加工效率。When using the device provided in this embodiment to carry out the horizontal electrolytic EDM process, due to the adoption of the horizontal machining method, the machining chips generated during the machining process can be discharged relatively easily under the action of gravity, which plays a role in the smooth discharge of the electrolytic erosion chips. This enhances the flow capacity of the electrolyte during processing and reduces the occurrence of short circuits and abnormal discharges; and due to the horizontal layout, the bubbles generated by the electrolytic reaction will be concentrated in the electrodes under the workpiece to be processed The surrounding area increases the stability of the air film, thereby effectively increasing the processing stability and processing depth; in addition, the horizontal layout can make up for the defect of conventional micro-EDM using a single longitudinal "point" processing method, and can carry out "line" Or "surface" processing and processing of thicker non-conductive material grooves, depending on the selection of electrodes, wire-cut processing can also be performed to increase the depth of EDM, expand the processing range, and improve processing efficiency.
实施例二Embodiment two
该实施例与实施例一的不同之处仅在于在电解箱底部设置了一套电极支撑装置8,其余结构均与实施例一中相同。The only difference between this embodiment and the first embodiment is that a set of electrode supporting device 8 is arranged at the bottom of the electrolytic box, and the other structures are the same as those in the first embodiment.
当工具电极3的长度较短时(<30 mm),加工过程中电极状态比较稳定,端部不会发生明显晃动,但是当工具电极3的长度较长时(≥30 mm),电解加工过程中会发生一定的抖动,进而可能会对加工过程稳定性和加工效果造成一定的影响,为了解决该问题,在电解箱1底部设置了电极支撑装置8,所述电极支撑装置8包括支撑杆81、活动块82和丝杆83,丝杆83水平置于电解箱1底部,丝杆83两端可转动地连接在电解箱1底部两侧设置的轴承块上且其一端穿出电解箱1后与第二伺服电机84相连,活动块82通过其内设置的丝杆螺母活动穿套在丝杆83上,支撑杆81固定在活动块82上,支撑杆81端部为锥形且其尖端与工具电极3端部相接触以起到支撑效果。当第二伺服电机84启动旋转,会带动丝杆83转动,在丝杆螺母的作用下,活动块82会将丝杆83的旋转运动转变为水平方向的移动,活动块82以1-10 mm/s的速度移动可带动支撑杆81灵活调节尖端位置以适应不同长度的长工具电极的支撑需要。When the length of the tool electrode 3 is short (<30 mm), the state of the electrode is relatively stable during the machining process, and there will be no obvious shaking at the end, but when the length of the tool electrode 3 is long (≥30 mm), the electrolytic machining process There will be a certain vibration in the process, which may have a certain impact on the stability of the processing process and the processing effect. In order to solve this problem, an electrode support device 8 is installed at the bottom of the electrolytic box 1, and the electrode support device 8 includes a support rod 81 , the movable block 82 and the screw mandrel 83, the screw mandrel 83 is placed horizontally at the bottom of the electrolytic box 1, and the two ends of the screw mandrel 83 are rotatably connected to the bearing blocks arranged on both sides of the bottom of the electrolytic box 1 and one end passes through the electrolytic box 1 Link to each other with the second servo motor 84, the movable block 82 is movably worn on the screw mandrel 83 by the screw nut provided therein, the support rod 81 is fixed on the movable block 82, the end of the support rod 81 is tapered and its tip is in line with the The ends of the tool electrodes 3 are in contact to play a supporting effect. When the second servo motor 84 starts to rotate, it will drive the screw mandrel 83 to rotate. Under the action of the screw mandrel nut, the movable block 82 will convert the rotary motion of the screw mandrel 83 into a horizontal movement. The movement at a speed of /s can drive the support rod 81 to flexibly adjust the position of the tip to meet the support needs of long tool electrodes of different lengths.
支撑杆81由耐强碱、耐腐蚀且不导电的聚四氟乙烯材料制成。The support rod 81 is made of strong alkali-resistant, corrosion-resistant and non-conductive polytetrafluoroethylene material.
丝杆83外层涂有强度高、耐腐蚀、绝缘的玻璃钢涂层。The outer layer of the screw mandrel 83 is coated with high-strength, corrosion-resistant, insulating fiberglass coating.
利用上述装置进行电解电火花加工的方法如下,其包括以下步骤:The method for utilizing the above-mentioned device to carry out electrolytic electric discharge machining is as follows, which includes the following steps:
a.安装在旋转主轴上的工具电极3处于待加工工件5下方,工具电极3长度<30 mm时,支撑杆81尖端与工具电极3不接触,工具电极3长度≥30 mm时,启动第二伺服电机84带动支撑杆81水平移动直至支撑杆81的尖端与工具电极3自由端相接触支撑;a. The tool electrode 3 installed on the rotating spindle is under the workpiece 5 to be processed. When the length of the tool electrode 3 is less than 30 mm, the tip of the support rod 81 does not contact the tool electrode 3. When the length of the tool electrode 3 is ≥ 30 mm, start the second The servo motor 84 drives the support rod 81 to move horizontally until the tip of the support rod 81 is in contact with the free end of the tool electrode 3 for support;
b. 工件5在机床自带的进给调节系统6的带动下以一定速度做进给运动,与此同时启动电源4,在电源4控制下,浸入电解液中的工具电极3表面发生电化学反应,在工具电极3表面产生气泡,气泡经过聚集产生气膜,进而在工具电极3表面和气泡外表面形成电势差,击穿电极表面的气泡发生放电,从而对非导电的工件5进行电火花蚀除;b. Driven by the feed adjustment system 6 of the machine tool, the workpiece 5 is fed at a certain speed. At the same time, the power supply 4 is turned on. Under the control of the power supply 4, an electrochemical reaction occurs on the surface of the tool electrode 3 immersed in the electrolyte. reaction, bubbles are generated on the surface of the tool electrode 3, the bubbles are gathered to form a gas film, and then a potential difference is formed on the surface of the tool electrode 3 and the outer surface of the bubbles, and the bubbles that break down the surface of the electrode are discharged, thereby performing spark erosion on the non-conductive workpiece 5 remove;
c. 进给调节系统6带动工件5继续以稳定的速度做进给运动,直到完成对工件的加工。c. The feed adjustment system 6 drives the workpiece 5 to continue the feed motion at a stable speed until the processing of the workpiece is completed.
图2是工具电极3为长度<30 mm的短圆柱体状电极时的加工示意图。在该情况下,不需要利用电极支撑装置8支撑电极,水平设置的工具电极3由第一伺服电机71带动旋转加工,直到加工完成。Fig. 2 is a schematic diagram of processing when the tool electrode 3 is a short cylindrical electrode with a length < 30 mm. In this case, there is no need to use the electrode supporting device 8 to support the electrode, and the tool electrode 3 arranged horizontally is driven by the first servo motor 71 to rotate and process until the process is completed.
图3是工具电极3为长度≥30 mm的长圆柱体状电极时的加工示意图。在该工况下需使用电极支撑装置8支撑电极,具体是启动第二伺服电机84带动支撑杆81水平移动直至支撑杆81的尖端与工具电极3自由端端部相抵后停止移动,接着,工具电极3由伺服电机带动旋转加工,直到加工完成。Fig. 3 is a schematic diagram of processing when the tool electrode 3 is a long cylindrical electrode with a length ≥ 30 mm. Under this working condition, it is necessary to use the electrode support device 8 to support the electrode. Specifically, start the second servo motor 84 to drive the support rod 81 to move horizontally until the tip of the support rod 81 touches the free end of the tool electrode 3 and stops moving. Then, the tool The electrode 3 is driven by the servo motor to rotate and process until the process is completed.
以上显示和描述了本发明的基本原理、主要特征及优点。但是以上所述仅为本发明的具体实施例,本发明的技术特征并不局限于此,任何本领域的技术人员在不脱离本发明的技术方案下得出的其他实施方式均应涵盖在本发明的专利范围之中。The basic principles, main features and advantages of the present invention have been shown and described above. However, the above descriptions are only specific embodiments of the present invention, and the technical features of the present invention are not limited thereto. Any other implementations that are obtained by those skilled in the art without departing from the technical solutions of the present invention should be included in the present invention. within the scope of the invention patent.
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