电极丝随动放电切槽技术试验研究

微细电火花线切割加工时电极丝存在难以避免的振动,且振动幅度随着切割工件厚度的增加而变大,这导致加工出现腰鼓形误差,工件加工效率与加工质量也受影响。针对电极丝的振动问题提出一种电极丝随动放电切槽技术,通过顶丝头的导丝孔和导丝槽抑制电极丝振动,利用电极丝放电蚀除工件完成了长度70 mm、直径0.1 mm的半圆截面长通道的加工。多次测量结果表明,所得深槽尺寸极限公差小于3μm,表面粗糙度在Ra31~56 nm,形状精度高、成形尺寸好,且特征宽度不受长度影响,扩展了微细电火花机床的应用范围,为工件的跨尺度加工提供了一种创新方案。

Experimental Study on Electrode Wire Servo Discharge Grooving Technology

The electrode wire has unavoidable vibration in the micro wire electrical discharge maching(micro-WEDM),and the vibration amplitude becomes larger with the increase of the workpiece thickness,which will lead to waist drum-shaped error and the decline of the machining efficiency and surface quality.In view of the vibration of the electrode wire,a wire servo discharge grooving(WSDG)method was proposed,which can suppress the electrode wire vibration through the guide hole and guide groove of the wire jackscrew,meanwhile the channel with a length of 70 mm and a diameter of 0.1 mm is processed by using WSDG method to erode the workpiece.Multiple measurement results showed that the size deviation of deep groove was better than 3μm,and the surface roughness was between Ra31 nm and Ra56 nm.The shape accuracy and forming size of the workpiece was satisfactory,and the feature width was not affected by workpiece length.The method expands the application range of micro-EDM and provides an innovative scheme for cross-scale machining of workpiece.