螺旋锥齿轮摆辗成形凹模电极的设计与制造

螺旋锥齿轮摆辗成形凹模通常采用电火花加工,用于电火花加工的电极对于模具型腔的制造精度具有重要影响.对螺旋锥齿轮与工具电极尺寸传递规律进行研究,并在此基础上设计凹模工具电极.最后对设计的电极齿形进行加工和检测,为齿轮摆辗成形凹模电极设计制造提供了科学依据.     

在普通电火花机床上加工斜齿型腔

我们曾加工了一种斜齿轮模具,该模具的加工关键在于斜齿型腔的加工。斜齿型腔由于齿部有螺旋升角,电火花加工斜齿形腔,电极提升就必须按照斜齿的螺旋转提升。在此情况下我们在D6140型电火花机床上,设计制造了一套螺旋提升夹具。     

精锻直齿锥齿轮模具电极的检测

采用微机编程计算、绘制标准齿形的一种新检测方法，对电火花加工直齿锥齿轮模具所用的紫铜电极齿轮的齿形进行了检测。使用这一方法检测电极齿轮，可获得高的检测精度，因此能保证制造出精度高的精锻模具及获得合格的精锻件。     

带爪齿轮精锻成形模的结构与加工制造

带爪齿轮目前被广泛应用于各种摩托车的档位机构。本文重点介绍了此类产品精锻成形模具的组合结均及加工制造（包括齿爪部分的电极加工），采用可多次复位的电火花成型加工工艺，改进了该模具的传统工艺方案，有效延长了模具的使用寿命。     

模具型腔电极的设计及其应用

以孔形型腔和手机模具型腔为例,探讨两种情形下电极的设计以及根据电极的实际加工尺寸和机床的加工参数表选择电火花加工参数的过程,以便在实践中更好地掌握电火花加工技术。     

转向直拉杆锻模型腔的电火花加工

以微型车转向直拉杆零件锻模型腔的电火花加工为例 ,对锻模型腔的电火花加工方法 ,电极的设计方案与制造工艺进行了分析和探讨 ,提出了一种可以保证模具型腔有足够重复精度的电火花加工电极的设计与制造方法     

叶轮注射模设计与制造

分析了水表中的重要零件—塑料叶轮的结构特点，设计了1副1模1腔、3点进料的注射模，介绍了该模具结构特点和工作过程，提出了模具型腔的电火花成型型腔和线切割加工电极的几种方法。     

关于型腔模电火花成型预加工余量探讨

任何机械加工的加工原则都是在保证质量的前提下,尽可能提高加工速度。型腔模电加工的加工原则,则是在尽可能减小工具电极相对耗损的前提下,缩短加工周期。确定型腔模预加工和电火花成型加工的步骤如下: 第一步:首先确定主要加工规准τ_k。影响工具电极耗损的最重要的因素是τ_k(脉冲宽度)。因此,型腔模具的电火花成型加工的全部工艺过程,其中包括各工艺环节,各项工艺措施的确定,均建立在确定了最     

一种微细电火花线切割用黑金丝设计及其应用研究

分析了形状复杂的微型孔和精密模具零件型腔微细电火花线切割加工过程中存在的问题，提出有效的解决方案。从应用角度出发，设计了复合重构表层黑金丝材料，优化了电极丝的放电性能，满足了微细电火花线切割加工形状复杂微型孔和精密模具零件应用要求，提高了加工精度和表面质量。     

型腔电火花加工工艺规律及花模的加工

一、型腔电火花加工的工艺特点型腔电火花加工与型孔电火花加工不相同,前者的主要矛盾是掌握工具电极的损耗与精度问题,而后者的主要矛盾是控制放电间隙与精度问题。型腔电火花加工的特点有以下几个:1.工具电极的损耗要求少,最好是无损耗加工。这一点是关键,如果电极损耗较多,将会直接影响型腔的精度,特别在加工窄缝型腔、文字、表牌以及几何形状复杂的工艺美术型腔膜时,电极的低损耗要求显得格外重要。     

注射模复杂型腔EDM电极创新设计与研究

介绍了注射模复杂型腔的特点和加工难度,电火花加工所用石墨电极的优异性能以及在注射模制造过程中所用石墨电极的分类。重点探讨了针对复杂型腔EDM电极设计的传统方法、创新设计、造型以及加工等过程中针对节省材料、提高效率和质量的一些改进方法。     

A study of EDM and ECM/ECM-lapping complex machining technology

EDM (electrodischarge machining) and ECM (electrochemical machining)/ECM-lapping complex machining is investigated in this paper. First, EDM shaping and ECM finishing technology are investigated. These processes are carried out in sequence on the same machine tool with the same electrode (copper) and the same machining liquid (water). Two types of EDM and ECM complex machining are investigated. One is with a formed electrode, and the other is with simple-shape electrode scanning. The complex machining with electrode scanning is applied to produce small and various-shaped components without making a formed electrode. The EDM surface of 1 μm Ra is improved to 0.2 μm Ra by applying ECM. Second, in order to get a smoother surface, a new EDM and ECM-lapping complex machining technology is developed. The surface roughness of a machined hole is improved to 0.07 μm Ra by applying 2 min of ECM lapping. The surface finishing of a hole shape is demonstrated with the complex machining technology.     

电火花电解复合加工工作液浓度对电极损耗的影响研究

针对电火花电解复合加工的电极损耗问题,以模具钢为加工对象开展了电火花电解复合加工实验。分析了在不同极性和电极材料条件下,工作液浓度对电极相对损耗、电极形状变化规律及加工精度的影响。结果表明:合理控制工作液浓度能降低电极相对损耗及减小电极形状变化。     

Investigation of the effects of electrode orientation and fluid flow rate in near-dry EDM milling

This research investigates the effects of electrode lead and tilt angles and dielectric fluid flow rate on material removal rate, tool electrode wear ratio, and surface roughness in near-dry electrical discharge machining (EDM) milling process. Computational fluid dynamics (CFD) model is developed to predict the dielectric fluid flow rate and qualitatively compare with the experimentally measured EDM material removal rate. The optimum lead angle, which maximized material removal rate and minimized tool electrode wear ratio, was found. The decrease in the lead angle has a negative effect on the roughness of machined surface. The increase in tilt angle reduces the material removal rate and increases the tool electrode wear ratio. The change in tilt angle does not have a significant effect on the surface roughness and can be used to prevent gouging in finishing EDM milling. This study shows that the material removal rate is linearly proportional to the mass flow rate of air and kerosene mixture, the tool electrode wear ratio is inversely related to the mass flow rate of air and kerosene mixture, and the average surface roughness does not have a good correlation with the flow rate of the mixture.     

Attempts to fabricate micro injection molding tools and assemble molded micro parts on same EDM machine

An EDM method for manufacturing plastic micro gear pumps is proposed. Micro gates and cavities for mating gears are machined by EDM in both sides of a stainless steel foil, respectively. The foil is then transferred to an injection molding machine, and fixed to a mold to form mating gears by injection molding. The mating gears formed on the foils are then re-positioned on the EDM machine, released from the foil, and placed in a second foil pre-machined by EDM for the pump housing, using an ejector pin fabricated by reshaping the tool electrode used to machine the two foils.     

电火花成型电极的高速切削加工

现代机械切削加工中,高速切削（High Speed Cutting）是一重要的发展方向,已开始被广泛使用。以高速、高精度和大进给为主要特征的高速切削加工近几年来发展十分迅速。本文通过高速切削机床加工一个手机型腔模石墨电极的过程,介绍和探讨高速加工在电火花成型方面的应用。     

A comparative experimental study of machining characteristics in vibratory, rotary and vibro-rotary electro-discharge machining

This paper compares the effects of high- and low-frequency forced axial vibration of the electrode, rotation of the electrode, and combinations of these methods in respect of material removal rate (MRR), tool wear rate and surface roughness in die sinking electro-discharge machining (EDM) with a flat electrode (planing mode).

The results of the combined states of rotation and vibration at high and low frequency (vibro-rotary EDM) are compared in order to establish which combinations are most appropriate to different machining regimes (finishing, semi-finishing and roughing). It is found that the combination of high-frequency vibration and rotation of the electrode is effective in attaining a high MRR at a specified surface roughness (R_a). This case is modelled by stepwise linear regression. The significant parameters are found by analysis of variance (ANOVA) and the optimum machining parameter settings are obtained using overlay contour plots. The advantages of vibration and rotation are seen to combine in this new process when employed for die sinking EDM with a flat electrode.     

Tool path generation for 4-axis contour EDM rough machining

Contour or CNC EDM machining of free-form surfaces requires tool paths that are different from those used in mechanical milling although in geometry both processes are described by the similar model of intersection between the rotating tool and the workpiece. In this paper, special requirements on tool paths demanded by contour EDM machining are studied and a two-phase tool path generation method for 4-axis contour EDM rough milling with a cylindrical electrode is developed. In the first phase of the method, initial tool paths for virtual 3-axis milling are generated in a commercial CAD/CAM system—Unigraphics, which provides users with plenty of options in choosing suitable tool path patterns. From these tool paths, cutter contact (CC) points between electrode and workpiece are reversely calculated. In the second phase, considering the special requirements of EDM machining, which include discharging gap compensation, electrode wear compensation, DC arcing prevention, etc., the electrode is adjusted to an optimized interference-free orientation by rotating it around the CC points obtained in the previous phase. This new orientation together with the reference point of electrode is output as new tool path. The whole algorithm has been integrated into Unigraphics, machining simulations and tests have been conducted for 4-axis contour EDM rough machining.