WO2005097387A1 - Electrode for high-speed electrical discharge machining - Google Patents
Electrode for high-speed electrical discharge machining Download PDFInfo
- Publication number
- WO2005097387A1 WO2005097387A1 PCT/EP2005/050963 EP2005050963W WO2005097387A1 WO 2005097387 A1 WO2005097387 A1 WO 2005097387A1 EP 2005050963 W EP2005050963 W EP 2005050963W WO 2005097387 A1 WO2005097387 A1 WO 2005097387A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- layer
- conductivity
- core
- providing
- copper
- Prior art date
Links
- 238000009760 electrical discharge machining Methods 0.000 title claims abstract description 6
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 claims abstract description 36
- 239000010949 copper Substances 0.000 claims abstract description 34
- 229910000831 Steel Inorganic materials 0.000 claims abstract description 32
- 239000010959 steel Substances 0.000 claims abstract description 32
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims abstract description 31
- 229910052802 copper Inorganic materials 0.000 claims abstract description 31
- 239000011701 zinc Substances 0.000 claims abstract description 22
- HCHKCACWOHOZIP-UHFFFAOYSA-N Zinc Chemical compound [Zn] HCHKCACWOHOZIP-UHFFFAOYSA-N 0.000 claims abstract description 21
- 238000009834 vaporization Methods 0.000 claims abstract description 21
- 230000008016 vaporization Effects 0.000 claims abstract description 21
- 229910052725 zinc Inorganic materials 0.000 claims abstract description 21
- 230000004888 barrier function Effects 0.000 claims abstract description 20
- 229910052759 nickel Inorganic materials 0.000 claims abstract description 17
- 229910052782 aluminium Inorganic materials 0.000 claims abstract description 12
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims abstract description 12
- 229910045601 alloy Inorganic materials 0.000 claims abstract description 9
- 239000000956 alloy Substances 0.000 claims abstract description 9
- ATJFFYVFTNAWJD-UHFFFAOYSA-N Tin Chemical compound [Sn] ATJFFYVFTNAWJD-UHFFFAOYSA-N 0.000 claims abstract description 8
- 229910052793 cadmium Inorganic materials 0.000 claims abstract description 8
- BDOSMKKIYDKNTQ-UHFFFAOYSA-N cadmium atom Chemical compound [Cd] BDOSMKKIYDKNTQ-UHFFFAOYSA-N 0.000 claims abstract description 8
- 229910052799 carbon Inorganic materials 0.000 claims description 17
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims description 12
- 238000000034 method Methods 0.000 claims description 11
- 238000009792 diffusion process Methods 0.000 claims description 8
- 239000012535 impurity Substances 0.000 claims description 5
- 229910000570 Cupronickel Inorganic materials 0.000 claims description 4
- YOCUPQPZWBBYIX-UHFFFAOYSA-N copper nickel Chemical compound [Ni].[Cu] YOCUPQPZWBBYIX-UHFFFAOYSA-N 0.000 claims description 4
- 238000005482 strain hardening Methods 0.000 claims description 4
- 229910000975 Carbon steel Inorganic materials 0.000 claims description 3
- 239000010962 carbon steel Substances 0.000 claims description 3
- 238000005253 cladding Methods 0.000 claims description 3
- ZCDOYSPFYFSLEW-UHFFFAOYSA-N chromate(2-) Chemical group [O-][Cr]([O-])(=O)=O ZCDOYSPFYFSLEW-UHFFFAOYSA-N 0.000 claims description 2
- 238000005520 cutting process Methods 0.000 abstract description 2
- 239000011248 coating agent Substances 0.000 description 4
- 238000000576 coating method Methods 0.000 description 4
- 238000010438 heat treatment Methods 0.000 description 4
- 238000003754 machining Methods 0.000 description 4
- 239000000203 mixture Substances 0.000 description 4
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 description 3
- 238000005275 alloying Methods 0.000 description 3
- 229910052804 chromium Inorganic materials 0.000 description 3
- 239000011651 chromium Substances 0.000 description 3
- 238000011010 flushing procedure Methods 0.000 description 3
- 239000000463 material Substances 0.000 description 3
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 2
- XLOMVQKBTHCTTD-UHFFFAOYSA-N Zinc monoxide Chemical compound [Zn]=O XLOMVQKBTHCTTD-UHFFFAOYSA-N 0.000 description 2
- 229910001297 Zn alloy Inorganic materials 0.000 description 2
- 230000008901 benefit Effects 0.000 description 2
- 238000010622 cold drawing Methods 0.000 description 2
- 238000001704 evaporation Methods 0.000 description 2
- 230000008020 evaporation Effects 0.000 description 2
- 239000012530 fluid Substances 0.000 description 2
- 230000008569 process Effects 0.000 description 2
- 230000009467 reduction Effects 0.000 description 2
- ZOXJGFHDIHLPTG-UHFFFAOYSA-N Boron Chemical compound [B] ZOXJGFHDIHLPTG-UHFFFAOYSA-N 0.000 description 1
- PWHULOQIROXLJO-UHFFFAOYSA-N Manganese Chemical compound [Mn] PWHULOQIROXLJO-UHFFFAOYSA-N 0.000 description 1
- 229910000990 Ni alloy Inorganic materials 0.000 description 1
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 1
- KOMIMHZRQFFCOR-UHFFFAOYSA-N [Ni].[Cu].[Zn] Chemical compound [Ni].[Cu].[Zn] KOMIMHZRQFFCOR-UHFFFAOYSA-N 0.000 description 1
- 238000004026 adhesive bonding Methods 0.000 description 1
- 229910052796 boron Inorganic materials 0.000 description 1
- 230000008859 change Effects 0.000 description 1
- 238000005260 corrosion Methods 0.000 description 1
- 230000007797 corrosion Effects 0.000 description 1
- 239000007772 electrode material Substances 0.000 description 1
- 229910052742 iron Inorganic materials 0.000 description 1
- 229910052748 manganese Inorganic materials 0.000 description 1
- 239000011572 manganese Substances 0.000 description 1
- 230000001846 repelling effect Effects 0.000 description 1
- 229910052710 silicon Inorganic materials 0.000 description 1
- 239000010703 silicon Substances 0.000 description 1
- 229910001220 stainless steel Inorganic materials 0.000 description 1
- 229910052720 vanadium Inorganic materials 0.000 description 1
- LEONUFNNVUYDNQ-UHFFFAOYSA-N vanadium atom Chemical compound [V] LEONUFNNVUYDNQ-UHFFFAOYSA-N 0.000 description 1
- 239000011787 zinc oxide Substances 0.000 description 1
Classifications
-
- 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
- B23H7/00—Processes or apparatus applicable to both electrical discharge machining and electrochemical machining
- B23H7/02—Wire-cutting
- B23H7/08—Wire electrodes
Definitions
- the present invention relates to an electrode for electrical discharge m achining.
- the present invention relates to a method of tuning various properties of such an electrode such as mechanical tensile strength, electrical conductivity and m achinability.
- Electro-discharge machining uses pulsed DC waves to create sparks between a work piece and electrode m aterial in a dielectric fluid.
- the electrode material is a wire. Parts of the electrode and work piece material are flushed away.
- An electrode wire for electrical discharge machining must meet various severe requirements. The most important requirements relate to electrical conductivity, mechanical strength and machinability. With respect to the first requirement, electrical conductivity, the electrode should be able to carry the currents without excessive heating so as to avoid breaking. The electrical current applied to the electrode m ay amount to 500 A and m ore. So the overall electrical resistance of the wire is important.
- the electrode is subject to tensions during working.
- a minimum tensile tension or load is required in order to avoid the electrode from repelling away from the work piece or in order to avoid the electrode from vibrating. This minimum tension must be able to be maintained despite temperatures sometimes increasing up to 300 °C.
- the eroded debris m ust be removed quickly in order to prevent local shortcuts.
- This m achinability is determined by the flushing rate of the dielectric fluid together with the nature of the electrode, more particularly the outer layer of the electrode.
- Various attem pts have been m ade in the prior art to meet all these requirements.
- CH-A5- 646 083 discloses an electrode for electrical discharge machining comprising a steel core, an intermediate copper layer and various copper- zinc- nickel alloy layers. I n this way a steel core m ay be covered by following subsequent layers : a copper layer, a Cu 5 Ni 55 layer, a Cu 3 oNi 45 Zn 25 layer and a Cu 30 Ni 2 oZn 5o layer. The purpose is to change gradually the properties from one layer to another layer and to avoid sudden changes.
- WO- A- 98/09764 discloses an electrode for discharge machining comprising a steel core, an intermediate layer of copper or a copper containing alloy, and an outer layer containing at least 40% of zinc.
- Su m m ary of the invention It is an object of the present invention to avoid the drawbacks of the -prior art. -r It is another object of the present invention to provide an alternative electrode for discharge m achining. It is still an object of the present invention to tune in a straightforward way and independently of each other the various properties of an electrode for discharge machining.
- an electrode for electrical discharge machining where the electrode comprises a) a core out of steel wire ; b) a conductivity layer of copper or aluminum around the core ; c) a barrier layer of nickel on the conductivity layer ; d) a vaporization layer of tin, zinc, lead or cadmium or any alloy thereof on the barrier layer.
- the steel wire may be a carbon steel or a stainless steel wire. With respect to a carbon steel wire, the am ount of carbon in the steel composition, possibly together with the amount of micro- alloying elements such as chromium, and the degree of work hardening of the steel wire determine the ultim ate tensile strength of the electrode. Work hardening can be done by cold drawing.
- the thickness of the conductivity layer and the quality of the copper or aluminum determine the electrical conductivity of the electrode and the speed of cutting.
- the thickness of the vaporization layer and the material selected for the vaporization layer determine the speed of flushing away any eroded debris during working.
- the conductivity layer is formed by cladding copper or aluminum around the steel core.
- Cladding provides an economical way of applying a relatively thick layer around the steel core.
- the conductivity layer is made of copper and a diffusion layer- copper nickel is present between the conductivity layer and the barrier layer of nickel.
- This diffusion layer starts from almost pure copper.
- the vaporization layer comprises pure zinc and unavoidable impurities.
- a vaporization layer gives excellent machinability to the electrode.
- all the layers are made of a material with a single purpose : a) a core out of steel for giving the mechanical strength ; b) a conductivity layer of copper or aluminum for the appropriate electrical conductivity ; c) a barrier layer of nickel to give a thermal resistance and to prevent sparks from damaging the core ; d) a vaporization layer of zinc for a fast flushing of the eroded debris and a stable discharge.
- the vaporization layer may be further provided with an oxide layer on the vaporization layer.
- This oxide layer may be a zinc oxide or may be a chromate.
- This oxide layer which is deliberately provided, has the advantage of preventing corrosion of the rest of the wire and of preventing flaking of the vaporization layer.
- a method of tuning the various functions of an electrode for electric discharge m achining comprises the following steps : a) providing a core out of steel wire ; b) providing a conductivity layer of copper or aluminum around the core ; c) providing a barrier layer of nickel on the conductivity layer ; d) providing a vaporization layer of tin, zinc, lead, cadmium or an alloy thereof around the barrier layer.
- the mechanical tensile strength may be tuned by selecting the proper amount of carbon in the wire rod composition - possibly together with the amount of micro- alloying elements such as chromium - and by applying the amount of work hardening, e.g. the am ount of cross- sectional reduction during cold drawing.
- the degree of electrical conductivity is tuned by choosing the quality of copper or aluminum in the conductivity layer and by determining the thickness of the conductivity layer.
- the degree of machinability may be tuned by the choice of the m aterial in the vaporization layer and by determining the thickness of the vaporization layer. Brief descri ption of the draw ings.
- FIGURE 1 is a cross- section of an electrode for electric discharge m achining according to the invention.
- FIGURE 1 is a cross-section of an electrode wire 10 for electric discharge machining according to the invention.
- the electrode wire 1 0 comprises a steel core 12.
- the steel core 12 is covered by a conductivity layer 14 of copper.
- On the conductivity layer is a diffusion layer 16 nickel - copper.
- Around the diffusion layer 16 is a barrier layer 18 of nickel.
- On the barrier layer 18 is a vaporization layer 20 of zinc.
- Such an electrode wire 10 for electrical discharge m achining may be m ade as follows.
- a steel core wire m ay have a low carbon content (lower than 0.20 %C) or a high carbon content (higher than 0.20 %Cj .
- a suitable steel composition may be along following lines : a carbon content ranging from 0.20 to 1 .10 %, a silicon content ranging from 0.10 to 0.50 %, a manganese content ranging from 0.20 to 0.75 %, the remainder being iron, possible micro- alloying elements such as chromium, boron, vanadium and unavoidable impurities.
- a copper strip is cladded around a steel core wire.
- the cladded steel wire is drawn until an intermediate diameter.
- a heat treatment is carried out on the drawn cladded steel wire. The nature of the heat treatment depends upon the carbon content in the steel wire. For low carbon contents, i.e. below 0.20 % C, the cladded steel wire is subject to a glueing treatment. For higher carbon contents, i.e. higher than 0.20 % C, the cladded steel wire is patented.
- a nickel coating is deposited on the copper layer. This is done by means of an electrolytic process. A diffusion layer copper - nickel m ay be formed. Thereafter, a zinc layer is deposited on the nickel layer by means of a hot dip layer.
- the nickel layer prevents a zinc alloy or zinc diffusion layer to be formed.
- the top layer of zinc is - apart from unavoidable impurities - a layer of pure zinc without brittle zinc alloy layers.
- the zinc layer may be deposited by means of an electrolytic process. After the hot dip bath or the electrolytic coating with zinc, the wire is drawn until its final diameter. Performing the drawing operation after the zinc coating has the advantage of facilitating the drawing : higher speeds or less expensive drawing dies can be used than in case the wire is drawn with a nickel top coating.
- IACS is the I nternational Annealed Copper Standard.
- the elongation is the percentage elongation after fraction.
- CCS stands for copper cladded steel.
- the steel core allows for a tunable tensile strength of the complete electrode (conductivity, barrier and evaporation layer included) in a broad range from 500 MPa to 1500 MPa, depending upon the steel composition (m ainly the carbon content) , the degree of final reduction and obviously the relative amount of mainly copper on the electrode.
- the 500 MPa is obtainable by means of low carbon contents ( ⁇ 0.20 % C) , the higher levels require higher levels of carbon content, which m ay range up to 0.70 and 0.80 % and even up to 0.95% and more.
- a copper clad steel core allows for tunable conductivity in a range from 15 % IACS to 85 % IACS, e.g. from 20 % IACS to 75 % IACS.
- I n order to obtain a 30% IACS 25 volume per cent of copper is needed, to obtain 40% IACS 36 volume per cent of copper is required, to obtain 55% IACS 52 volume per cent of copper is required, to obtain 60% IACS 57 volume per cent of copper is required and to obtain 70 % IACS 68 volume per cent of copper is required.
- the thickness of the barrier layer in nickel may range from less than 1 ⁇ m to more than 10 ⁇ m, e.g. from 1 ⁇ m to 8 ⁇ m, e.g. from 2 ⁇ m to 7.5 ⁇ m.
- the thickness of the evaporation layer of zinc may range from 5 ⁇ m to
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- Chemical & Material Sciences (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Electrochemistry (AREA)
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Electrical Discharge Machining, Electrochemical Machining, And Combined Machining (AREA)
Abstract
Description
Claims
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
EP04101349 | 2004-04-01 | ||
EP04101349.1 | 2004-04-01 |
Publications (1)
Publication Number | Publication Date |
---|---|
WO2005097387A1 true WO2005097387A1 (en) | 2005-10-20 |
Family
ID=34928934
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/EP2005/050963 WO2005097387A1 (en) | 2004-04-01 | 2005-03-04 | Electrode for high-speed electrical discharge machining |
Country Status (1)
Country | Link |
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WO (1) | WO2005097387A1 (en) |
Cited By (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN102971102A (en) * | 2010-06-04 | 2013-03-13 | 铃木金属工业株式会社 | Electrode wire for electrical discharge machining |
US20140091821A1 (en) * | 2012-09-28 | 2014-04-03 | David Shia | Composite wire probes for testing integrated circuits |
DE102013009767A1 (en) * | 2013-06-11 | 2014-12-11 | Heinrich Stamm Gmbh | Wire electrode for spark erosive cutting of objects |
CN105057802A (en) * | 2015-08-10 | 2015-11-18 | 江苏塞维斯数控科技有限公司 | Heat-resisting tool for linear cutting machine tool |
US9849531B2 (en) * | 2013-09-09 | 2017-12-26 | Sumitomo Electric Industries, Ltd. | Electrode wire for wire electric discharge machining, and method for producing same |
Citations (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JPS5914429A (en) * | 1982-07-10 | 1984-01-25 | Sumitomo Electric Ind Ltd | Composite wire for wire-cut electric discharge machining electrode wire and manufacturing method thereof |
CH646083A5 (en) * | 1982-02-18 | 1984-11-15 | Charmilles Sa Ateliers | Wire electrode for erosive electrical discharge machining |
JPS61279433A (en) * | 1985-05-31 | 1986-12-10 | Furukawa Electric Co Ltd:The | Electrode wire for wire electric discharge machining and manufacture thereof |
EP0794026A1 (en) * | 1996-02-26 | 1997-09-10 | Sprint Métal - Société de Production Internationale de Tréfiles | Process for the production of a composite wire of small diameter, in particular a wire electrode for electro-discharge machining and a wire electrode obtained thereby |
WO1998009764A1 (en) * | 1996-09-04 | 1998-03-12 | Berkenhoff Gmbh | High-strength erosion electrode |
-
2005
- 2005-03-04 WO PCT/EP2005/050963 patent/WO2005097387A1/en active Application Filing
Patent Citations (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CH646083A5 (en) * | 1982-02-18 | 1984-11-15 | Charmilles Sa Ateliers | Wire electrode for erosive electrical discharge machining |
JPS5914429A (en) * | 1982-07-10 | 1984-01-25 | Sumitomo Electric Ind Ltd | Composite wire for wire-cut electric discharge machining electrode wire and manufacturing method thereof |
JPS61279433A (en) * | 1985-05-31 | 1986-12-10 | Furukawa Electric Co Ltd:The | Electrode wire for wire electric discharge machining and manufacture thereof |
EP0794026A1 (en) * | 1996-02-26 | 1997-09-10 | Sprint Métal - Société de Production Internationale de Tréfiles | Process for the production of a composite wire of small diameter, in particular a wire electrode for electro-discharge machining and a wire electrode obtained thereby |
WO1998009764A1 (en) * | 1996-09-04 | 1998-03-12 | Berkenhoff Gmbh | High-strength erosion electrode |
Non-Patent Citations (2)
Title |
---|
PATENT ABSTRACTS OF JAPAN vol. 0081, no. 00 (M - 295) 11 May 1984 (1984-05-11) * |
PATENT ABSTRACTS OF JAPAN vol. 0111, no. 46 (M - 587) 13 May 1987 (1987-05-13) * |
Cited By (8)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN102971102A (en) * | 2010-06-04 | 2013-03-13 | 铃木金属工业株式会社 | Electrode wire for electrical discharge machining |
EP2578343A4 (en) * | 2010-06-04 | 2014-04-30 | Suzuki Metal Industry Co Ltd | ELECTRODE WIRE FOR ELECTRIC DISCHARGE MACHINING |
US20140091821A1 (en) * | 2012-09-28 | 2014-04-03 | David Shia | Composite wire probes for testing integrated circuits |
US9207258B2 (en) * | 2012-09-28 | 2015-12-08 | Intel Corporation | Composite wire probes for testing integrated circuits |
DE102013009767A1 (en) * | 2013-06-11 | 2014-12-11 | Heinrich Stamm Gmbh | Wire electrode for spark erosive cutting of objects |
EP3007847A1 (en) * | 2013-06-11 | 2016-04-20 | Heinrich Stamm GmbH | Wire electrode for the electric discharge cutting of objects |
US9849531B2 (en) * | 2013-09-09 | 2017-12-26 | Sumitomo Electric Industries, Ltd. | Electrode wire for wire electric discharge machining, and method for producing same |
CN105057802A (en) * | 2015-08-10 | 2015-11-18 | 江苏塞维斯数控科技有限公司 | Heat-resisting tool for linear cutting machine tool |
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