模具型腔三维曲面的电火花套型加工

简单介绍了电火花套型加工的基本规律,分析了采用复杂形状电极套型加工复杂型腔的特性和困难,着重阐述了采用简单形状电极套型加工三维曲面模具型腔的工艺方法,包括电极制作,加工路径选定,程序编写及加工轨迹的简单仿真。最后展示了用这种工艺所加工的模具型腔和型芯。     

电火花套型加工中工艺步骤对加工效果的影响的探讨

介绍了电火花套型加工研究中所用的实验设备、工具和加工电规准,阐述了所采用的数控加工程序的编制,不同的工艺步骤的实施方法和加工的模具型腔和型芯.对不同的工艺步骤的的加工结果进行了分析对比和归纳小结,最后总结了工艺步骤对加工效果影响的结论.     

电火花加工中电极材料对加工性能影响的试验研究

以电火花多电极加工3Cr13模具型腔为研究对象,以提高材料去除率和降低电极损耗为目标,对负极性标准切入加工时不同电极材料的电火花加工性能(加工效率、电极损耗)进行研究,设计并进行了不同工艺参数下紫铜电极和Cu50W铜钨合金电极加工试验,获得了不同条件下的材料去除率和电极相对损耗参数,并对多电极电火花加工工艺及经济性进行了分析,结果表明:相同工艺参数下,加工性能因电极材料热学性能不同而不同,Cu50W铜钨合金的材料去除率约为紫铜的85.7％,而电极相对损耗约为紫铜的42.9％,从而为电火花加工不锈钢模具材料的电极选择提供了理论依据.     

第18篇 曲轴电极的加工难点

问题现场描述 制造复杂的模具,需要电火花机床加工模具的型腔,加工型腔离不开电极,电极的质量直接影响模具的质量。我们这里采用石墨作为电极的材料,用150mm立体仿形铣床（见图1）加工曲轴电极。由于设备落后、效率低,加工的电极很难达到工艺要求。     

遥控器面板注射模具设计与数控加工

较为详尽地讲述了遥控器面板注射模设计、前后模铜电极拆分的原理和方法,并对模具型腔、型芯和铜电极进行了细致的数控加工工艺分析.     

微细锥孔的电火花加工

锥孔加工通常用于以下几种情况：型腔模具的侧壁；冲模的刃口斜角或落料模的落料角；零件中的锥孔。数值很小的锥角，可以通过改变电加工过程中的电参数或利用二次放电现象来实现，较大的锥角则需要利用锥形电极做电火花加工。本文只讨论用锥形电极加工锥孔的电火花加工工艺，而不涉及线电极切割电火花加工方式。     

莫具加工中电极材料的含理选择及应用

在模具加工中,特别是成形模具的型腔加工中,采用电火花加工技术目前仍然是不可替代的加工手段。其中工具电极的合理选择是一项重要的工作,这点在生产实践中并没有得到足够的重视。一般来说,对于模具本身材料,在设计之初就根据所成形材料特点和生产要求等条件来合理选择。对于需要电火花加工的型腔,由于被加工模具材料性能和工具电极材料性能将影响电火花加工性能（材料去除率、工具损耗率及工件表面质量等）,因此对于需要采用电火花加工的型腔来说,所用的工具电极也需要慎重对待,这样才能制造出高质量的模具。     

塑料夹子模具铜电极的设计与数控加工

1.引言 电火花加工通常采用易于加工的铜作放电电极。用于制作模具的材料比较硬，模具型腔中有深孔、窄槽及尖角，受刀具的硬度和规格尺寸等特性限制，无法用数控铣加工去除全部残料，尤其是前模（一般是凹槽），此时可用电火花加工。通常前、后模制造时需要与之配套的铜电极。加工铜电极时要设计加工分中面和校表面。     

电火花成形加工中工具电极定位新方法

电火花成形加工常常是模具制造流程中重要的一环，随着电加工技术的不断发展，以及电火花加工在模具制造中的广泛应用，为提高电火花加工的质量和效率，一般常重视研究放电加工工艺参数对质量和效率的影响，而很少研究工具电极定位和夹紧对电火花加工的质量和效率的影响。经多年电火花加工实践，合理采用一定的夹具和辅具，使工具电极有稳定的定位精度并缩短定位时间，对提高电火花加工效率和精度有显著的作用。     

集束电极电火花加工模具型腔的技术研究

在电火花型腔成型加工中,采用分步法,先采用集束电极快速仿形成型进行粗加工,再采用成型电极进行电火花成型精加工,避免了电火花型腔粗加工中复杂结构成型电极的制作,提高加工效率。基于花瓣式锥形电极夹头,研发了新型快速夹持集束电极装置,进行集束电极电火花成型加工工艺试验,摸索了不同电火花加工参数对电火花加工性能的影响,并实现了复杂型腔的加工。     

Investigating and removing the re-sticky debris on tungsten carbide in electrical discharge machining

Electrical discharge machining (EDM) is an excellent method to machine tungsten carbide with high hardness and high toughness. However, debris from this material produced by EDM re-sticking on the workpiece surface remarkably affects working efficiency and dimension precision. Therefore, this study investigated the re-sticky phenomenon of tungsten carbide and how to reduce the debris re-sticking on the workpiece surface. In general, the polarity in EDM depended on the different electrical parameters of the machine input and the different materials of the tool electrode. The first item of investigation observed the re-sticky position of the debris to study the effect of different polarities during the EDM process. Next, the tool electrode was set at different conditions without rotation and with a 200 rpm rotational speed to evaluate the rotating effect in EDM. Finally, different lift distances of the electrode and different shapes of electrode with rotation were utilized to investigate the improvement for reducing debris re-sticking on the machining surface. The results showed that only negative polarity in EDM could cause the re-sticky phenomenon on tungsten carbide. On the other hand, debris would notably re-stick on any machining position when the tool electrode was not rotated in EDM. Besides, debris significantly stuck on the center of the working area with rotation of the electrode. Additionally, a larger lift distance of the tool electrode could reduce debris re-sticking on the working surface, but this process would decrease material removal rate in EDM. In the end, a special shaped design of the tool electrode resulted in the re-sticky debris completely vanishing, when the electrode width was 0.6 times the diameter of this cylindrical electrode.     

微细电火花加工中电极材料的蚀除机理研究

在微细电火花加工过程中 ,由于放电时间极短 ,使得其阴阳两极的电极材料蚀除过程产生较大的差异。本文应用传热学和电场的基本理论 ,分别对微细电火花加工阴阳两极的材料蚀除机理进行了理论研究 ,得出了在窄脉宽微细电火花加工中 ,尽量缩短脉宽可提高阳极材料的去除效率 ,同时又不会明显增加阴极材料损耗的结论。为微细电火花加工脉冲电源设计及加工工艺的改进提供了理论依据     

超短脉宽电火花加工工件表面蚀除模型分析

分析了在电火花加工中单脉冲超短脉宽放电情况下,工件电极表面蚀除凹坑的形成机理,并建立了凹坑形成的数值模型,应用ANSYS对所建模型进行了仿真模拟,最后进行了单脉冲电火花放电去除验证性试验,对尖孔蚀除模型进行了验证,取得了较理想的结果。     

电极丝自旋式电火花线切割加工

提出了一种全新的电极丝高速自旋的电火花线切割加工方法。论述了这种新方法中存在的一系列特殊效应及由此而带来在加工精度、表面粗糙度和加工效率方面的独持优越性。按此原理设计构成的新一代电火花线切割机床，可以有一个突破性发展。     

Advantages of carbon nanotubes in electrical discharge machining

Carbon nanotubes (CNTs) have a small specific gravity and a straight-pin shape, which allow them to continuously float and to uniformly disperse throughout the entire dielectric-filled cavity with little agglomeration during electrical discharge machining (EDM). In the past, powder mixtures of silicon, aluminum, and chrome have been used in the EDM process. However, there are concerns about flushing the controlled gap between the electrode and the workpiece because of their heavy specific gravity and their associated non-uniform dispersion in the dielectric. In this study, the effect of adding CNT powders to the dielectric on the surface integrity and the machining efficiency of the workpiece were investigated. CNTs can avoid the agglomeration problem. The CNTs were fabricated by chemical vapor deposition and added to the dielectric at a concentration of 0.4?g/l. The average surface roughness of 0.09?μm was achieved within 1.2?h, and the material defects of the recast layer and the micro-cracks were considerably reduced. The adopted processing parameters were a negative electrode polarity, a discharge current of 1?A, a pulse duration of 2?μs, an open-circuit voltage of 280?V, and gap voltage of 70?V. This technology improved the surface finish by 70% and the machining time by 66%. The achievement is attributed to the nanoscale characteristics of the CNTs in the dielectrics. The surface force became large and was able to balance the gravity body force of the CNTs. Consequently, the electric arcs were well dispersed and more uniform across the electrode gap, thus significantly enhancing the performance of the electrical discharge. It is expected that carbon nanotubes will be used in many EDM applications.     

导电CVD金刚石电极电火花精微加工研究

将导电CVD金刚石厚膜用作电火花加工的电极，研究了其精微加工特性。实验显示，导电CVD金刚石电极在窄脉宽精微加工条件下的损耗极低，几乎为零；且在某些条件下导电CVD金刚石电极的加工效率优于铜电极。研究结果初步表明导电CVD金刚石有着优异的电火花加工性能。     

整体叶环成组电极电火花高效加工技术研究

为提高整体叶环电火花加工总体效率,针对整体叶环结构特点,提出了一种成组电极多流道同时加工方案。以典型整体叶环为例,详细论述了该方案中的关键技术,包括成组电极型面、进给轨迹及展成运动轨迹设计等。基于关键技术的解决,通过工艺试验对方案进行验证,并试制加工出合格的试验件。研究表明,采用成组电极对整体叶环进行电火花加工,能够提高脉冲利用率,有效缩短带冠叶环制造周期。     

基于灰关联分析的电火花刻槽工艺参数优化

为了获得较高的加工质量和加工效率,在对加工时间、电极蚀损量、回退次数和表面粗糙度等指标进行综合分析的基础上,对电极材料、加工电压、峰值电流、脉冲宽度、脉冲间隔、正常进给速度以及快进速度等工艺参数进行了分析和优化.采用电火花刻槽机为实验工具进行正交试验,对正交试验的结果进行了直观分析和灰关联分析.对灰关联度进行F检验后,获得了显著的影响因素,最终遴选出最优加工参数.验证试验表明,灰关联分析法能简化复合工艺指标的优化选择,具有很好的应用效果.     

Energy distribution in cool electrode of electrical discharge machining based on wave-particle dualism

This paper studies the energy distribution in cool electrode of electrical discharge machining (EDM) on the basis of the wave-particle duality of matter. First, the movement of electrons and ions in the discharge channel was investigated in this article through the wavelength calculation of particles in a discharge channel. The main characteristic of electrons is wave and the moving form is prioritized for diffraction. Ions are mainly characterized by particles. These ions continuously vibrate in the mean free path. Second, a numerical calculation model is proposed on the basis of particle movement. The temperature field in the discharge channel of the cool electrode in the EDM to the titanium alloy is examined using the ANSYS software and simulation result is validated experimentally. Experimental results show that the diameter of the electric corrosion pit on the cool electrode surface is 355?μm, which is less than the electric corrosion pit diameter of 470?μm on a conventional electrode surface. Eventually, the EDM experiment was carried out under the same processing conditions with the cool electrode and the conventional electrode, respectively. The result shows that using cool electrodes in EDM can reduce electrode wear and increase machining efficiency.     

High efficiency fine boring of monocrystalline silicon ingot by electrical discharge machining

This article deals with high efficiency and high accuracy fine boring in a monocrystalline silicon ingot by electrical discharge machining (EDM). In manufacturing process of integrated circuits, a plasma-etching process is used for removing oxidation films. This process has recently been examined for use of monocrystalline silicon as the electrode to minimize the contamination. However, it is difficult to machine silicon accurately by the conventional diamond drilling method, because the material removal is due to brittle fracture. The machining force in the EDM process is very small compared with that in conventional machining, therefore, the possibility of high efficiency and high accuracy boring holes in silicon ingot by EDM is experimentally investigated. The removal rate of monocrystalline silicon by EDM is much higher than that of steel, while the electrode wear is extremely small. The improvement method leads to a better hole without chipping at the exit of hole or sticking of the insulator on the wall of hole. Furthermore, it is proved that even a high aspect ratio of about 200 boring is possible.