风扇注射模型腔和型芯的数控加工

在塑料注射模的加工中,型腔和型芯的加工任务最重,难度最大,主要涉及CNC和电火花成型加工,其中CNC刀路的编制是整个加工的中心任务,其好坏决定着CNC加工的质量和后续电火花成型加工的难易程度。本文主要阐述了Cimatron在风扇模具型腔和型芯加工中的应用,对风扇模具型腔和型芯加工进行了工艺分析,进而重点介绍了粗加工和精加工实现方法。最后,通过Cimatron刀路仿真模拟,验证本文方法中刀路的合理性。     

电火花加工拉伸模锥度型腔的新途径

对于小型硬质合金拉伸模具的锥度型腔,一般加工方法难以实施,我院在数控电火花加工机床上进行电火花成型加工,并采用单个直身电极平动扩展加工等先进工艺,获得了较高的加工质量和生产效率。     

数控精密电火花与线切割加工在现代模具加工中的应用

分析了数控精密电火花线切割加工技术及电火花成型加工技术在冲模及型腔模加工中的应用,探讨了电火花与线切割在模具加工应用中的几种特殊加工方法,如电火花线切割、电火花成型以及电火花微细孔机的特殊加工方法。     

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     

混粉电火花加工在型腔模中的应用

混粉电火花加工是一种改善电火花加工表面粗糙度与加工效率的先进工艺方法,近几年在像手机外壳模具、遥控器外壳模具等型腔模的电火花精加工中发挥着越来越重要的作用.通过对型腔模混粉电火花加工应用技术的探讨,对模具制造企业吸收与消化当前先进的电火花加工工艺具有实际的应用价值.     

手机外壳模具成型面电极设计与数控高速加工

分析了典型手机模具型芯、型腔、内外抽芯机构主要成型结构。以手机外壳模具型芯为研究对象,数控高速铣削加工和电火花放电加工结合的制造工艺为基础,阐述了手机外壳类典型的模具电极设计。以模具外型面成型电极为例详细介绍电极设计与数控高速加工过程与工艺优化,可作为同类型模具设计和制造工艺做参考。     

混粉电火花加工在模具型腔加工中的应用

针对模具型腔的混粉电火花加工应用技术进行了探讨,对模具制造企业吸收与消化当前先进的电火花加工工艺具有实际的应用价值。     

行输出高压骨架注塑模整体型腔的电火花加工

如图1所示整体型腔镶块简图为行输出高压骨架注塑的最关键零件,型腔复杂,精度要求高,所以成型加工难度大,用普通的机械加工方法无法成型。经过反复试验,采用电火花加工,成功地解决了该型腔的成型加工问题。在此基础上,研制成功了整体型腔行输出高压骨架注塑模具,为开创我国电视机行输出变压器的自动化生产攻克了一个重要技术关键。     

汽缸盖压铸模的电火花成型加工

<正> 摩托车汽缸盖压铸模是典型的较复杂的窄深槽型腔模具。南阳地区电加工学会最近为国营中原电梯厂完成了摩托车汽缸盖压铸模电火花成型加工任务。结束了该模具依靠进口的历史。本文针对该模具的结构、电极设计与制造、电加工规准选择等加工工艺作一介绍,供参考。     

《电加工》一九七三年总目录

(一)电火花加工 一、电火花加工机床与工艺部分编号题目稿件来源期页 1型腔模电火花加工工艺中国科学院电工研究所、北京低压 电器厂11 2 D6185型电火花加工机床主抽头的北京机床研究所,营口电火花机床 设计’厂244 3液压主轴头的设计和制造营口电火花机床厂41 4电火花加工整体叶轮叶片西北工业大学七O一教研室电加工 组61 5硬质合金冲裁模制造工艺上海电扇厂模具车间67 二、电火花加工电源部分编号题目稿件来源期页 1 KD一01型可控硅式电火花成型加中国科学院电工研究所、北京低压 工机床的电气线路电器厂114 2晶体管脉冲电源变压器式高…     

Real-time Tool Wear Compensation in Milling EDM

Accurate machining by milling EDM (i.e. CNC contouring EDM with a rotating cylindrical or tubular electrode) necessitates compensation of the tool electrode wear. Existing anticipated wear compensation is based on off-line tool wear simulation prior to machining. This can be combined with corrections based on periodical measurements of tool length during machining. Anticipated wear compensation involves an important restriction: an exact model of the blank geometry must be available in order to perform the tool wear simulation. This paper presents a new method of wear compensation. On-line estimation of tool wear is used for combining anticipated compensation with real-time compensation. This extends the scope of milling EDM to the machining of blanks of which the exact shape is not known in advance.     

日本放电加工的新方法和新技术

综述了日本在放电加工领域的最新研究动态，包括成形放电加工、微细放电加工和线切割放电加工三部分内容。在成形放电加工方面，主要介绍一项新技术——气中放电高速三维空腔铣的原理、实验装置及加工效果；在微细放电加工方面，主要介绍一种新近开发的可同时加工微细轴和微孔的自动微孔加工装置和目前已加工出的微细轴的最小尺寸；在线切割放电加工方面，主要介绍了提高圆角加工精度的新方法、提高放电位置可控性的新方法和新的硅锭切片方法。     

一种电火花加工螺纹电极的定位方法

介绍了一种电火花加工螺纹电极的定位方法,使得电火花加工螺纹型腔时,可以使用多个电极进行粗、精加工,达到提高螺纹精度及降低表面粗糙度值的目的,并可实现模具试模后对螺纹型腔的尺寸修整。     

A review on the conventional and micro-electrodischarge machining of tungsten carbide

The capability of machining intricate features with high dimensional accuracy in hard and difficult-to-cut material has made electrodischarge machining (EDM) process as an inevitable and one of the most popular non-conventional machining processes. In recent years, both EDM and micro-EDM processes are being used extensively in the field of mould making, production of dies, cavities and complex 3D structures using difficult-to-cut tungsten carbide and its composites. The objective of this paper is to provide a state of the art in the field of EDM and micro-EDM of tungsten carbide and its composites. The review begins with a brief introduction on the EDM and micro-EDM processes. The research and developments in electrodischarge machining of tungsten carbide are grouped broadly into conventional EDM of tungsten carbide, micro-EDM of tungsten carbide and current research trends in EDM and micro-EDM of tungsten carbide. The problems and challenges in the area of conventional and micro-EDM of tungsten carbide and the importance of compound and hybrid machining processes are discussed. A summary of the future research directions based on the review is presented at the final section.     

Electrical discharge machining using simple and powder-mixed dielectric: The effect of the electrode area in the surface roughness and topography

Electrical discharge machining (EDM) is one of the most widely disseminated manufacturing technologies, in particular as regards the generation of accurate and complex geometrical shapes on hard metallic components. Nevertheless current EDM technologies have major limitations when dealing with fine surface finish over large process area. Indeed this is one reason that explains the need of final manual polishing of mould cavities performed by EDM. Recently EDM with powder-mixed dielectric (PMD-EDM) has been a focus of an intense research work in order to overcome these technological performance barriers. This paper presents a research work within the objective to acquire deep knowledge on EDM technology with powder mixed dielectric and to compare its performance to the conventional EDM when dealing with the generation of high-quality surfaces. In particular the analysis of the effect of the electrode area in the surface quality measured by the surface roughness and craters morphology was carried out for both technologies. The results achieved evidenced a linear relationship between the electrode area and the surface quality measures as well as a significant performance improvement when the powder mixed dielectric is used.     

High Speed 3D Milling by Dry EDM

This paper describes the high speed EDM milling of 3D cavities using gas as the working fluid. In this new process, the molten workpiece material is removed and flushed out of the working gap with the help of high-pressure gas flow. The advantages or this technique are the remarkably small tool electrode wear and the significantly high material removal rate especially when oxygen gas is used due to the extremely strong oxidation of steel workpieces. Experiments showed that the material removal rate increases dramatically when the discharge power density on the wonting surface exceeds a certain threshold due to thermally activated chemical reaction between the gas and workpiece material. The maximum removal rate obtained was almost equal to that of high speed milling of quenched steel by a milling machine. The machining accuracy was considerably better when the gas was sucked through the pipe electrode than Jetted.     

Gap control for near-dry EDM milling with lead angle

A new gap control strategy for five-axis milling using near-dry electrical discharge machining (EDM) has been experimentally investigated. The conventional EDM control strategy only allows the retraction of the electrode in the direction of machining trajectory, which results in inefficient gap control when the electrode is not perpendicular to the workpiece. The new gap controller is capable of retracting the electrode in the direction of its orientation. This enables more efficient enlargement of the discharge gap leading to faster recovery of average gap voltage. Experimental results show a 30% increase in material removal rate while the tool electrode wear ratio and surface roughness are not affected. Furthermore, EDM efficiency is improved due to the change in the electrode retraction in its axial direction. The gain tuning of the proposed controller is also discussed. This study shows the direction of electrode retraction is important for five-axis near-dry EDM milling.     

基于UG/Open API的齿面侧铣精加工方法研究

将自由曲面的数控加工方法应用于大模数齿面加工中,采用多轴联动侧铣完成最终齿轮表面的精加工。为了使加工中刀具切触点能够与齿面相适应、减小刀具的磨损,利用UG NX的二次开发环境,对齿面加工的走刀轨迹进行控制。仿真结果表明:该方法能够较好地解决齿面加工中切触点固定的问题,有利于延长刀具寿命,提高加工效率。     

钢模型腔超塑成形与电火花复合加工

钢模型腔的电火花加工是常用的型腔加工技术 ,但加工效率较低。型腔超塑成形是型腔加工新技术之一 ,但需用高温合金凸模 ,且成形后需淬火强化而影响已成形型腔的精度。介绍了将2种技术优化组合的复合加工原理、实施方案及应用实例。该技术尤其适用于有批量要求的复杂高精度型腔的加工。     

电火花摇动加工微细阵列轴和孔的试验研究

针对微细阵列轴和孔的电火花加工,提出了利用数控电火花加工机床摇动功能的摇动加工微细阵列轴和孔的方法.此法是基于电火花反拷贝加工的原理,先用丝电极在薄平板(中间电极)上按要加工的阵列轴和孔间距或数倍间距加工阵列小孔(直径0.1 mm以上),然后用加工的薄平板(中间电极)作电极,电火花摇动加工微细阵列轴(电极),最后用此微细阵列电极加工阵列孔.进行了电火花摇动加工微细阵列电极试验,得到了单电极直径为50 μm、长径比为16的3×3阵列电极,并用此电极在70 μm厚的不锈钢板上加工出单孔直径为70 μm的3×3微细阵列孔.试验结果表明,电火花摇动加工方法可实现微细阵列轴和孔的加工.