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微细电火花加工及其关键技术 总被引:3,自引:0,他引:3
综述了微细电火花加工的基本原理及最新研究进展。比较了LIGA技术与微细电火花加工的特点与应用。简要分析了微细电火花加工的关键技术:微细电极的在线制作、微进给装置、微小能量的脉冲电源、微小电极的运动轨迹规划、电极的损耗及补偿策略。展望了微细电火花加工在微三维结构加工中的应用前景。 相似文献
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采用深度光刻与电铸技术相结合较好地解决了大深宽比的电火花工具电极的制造问题。在此基础上,利用优化的微细电火花加工工艺,可以实现大面积微细结构的高效、精细制造。 相似文献
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近年来,随着微细加工技术的发展,开发出各种不同的加工方法。有的有希望用来制造微型机器和医疗器械用的零件。就亚微米尺寸加工而言,目前,虽然溅射和蚀剂等加工方法在半导体制造方面占主流,但不适于复杂3维形状的加工。在此之前,电火花微孔加工已显示出高精度加工的效果。以往还曾利用圆柱形电极在低损耗条件下进行过轮廓加工。然而,当采用微小直径电极加工时,由于电极损耗大幅度增加,使电极瑞部棱角产生圆弧R,因而不能实现高精度加工。与上述情况相比,日本三菱公司却积极地利用电极损耗来保持加工底面的棱角,以谋求实现高精度微细形状的加工。一、简单电极轮廓加工原理微细轮廓电火花加工,主要采用微小直径的管状电极,使其在旋转状态下进行加工,以实现所要求的加工轮廓(图1)。在以往,主要是借助于圆柱状电极的侧面来进行轮廓加工见,如图2(a)所示,而微细轮廓加工则利用电极的底面,边反 相似文献
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设计了微细电极在线检测系统。系统由卤素灯光源、变焦显微镜头、CCD摄像机和6自由度支架组成,具有1.61 μm的分辨率和113~729的放大率。在Linux平台下,基于V4L2 API开发了图像采集程序,使用mmap()内存映射方法获取图像数据。实现了IplImage数据结构和QImage类的转换,使图像既可以基于OpenCV进行处理,又可以基于Qt进行显示,通过Canny边缘检测算法提取了微细电极的边缘轮廓。实现了电极在线观测的G代码功能,进行了块状电极电火花磨削微细轴的实验。实验结果表明系统可以在线观察电极状态和在线测量电极尺寸,在线测量值与扫描电镜离线测量值的相对误差在5%以内, 解决了微细电火花加工的微细电极在线制造和检测等难题。 相似文献
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微制造系统中的微细电火花加工技术 总被引:6,自引:0,他引:6
文章系统地研究和综述了微细电火花加工技术的研究现状和发展趋势,论述了微细电火花加工技术在微三维结构制作及微制造系统中的应用。 相似文献
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微细电火花加工的发展现状与展望 总被引:1,自引:0,他引:1
王克锡 《世界制造技术与装备市场》2000,(1):30-33
目前,尽管出现了各种不同的微细加工方法,但由于微细电火花加工法具有独特的优点,因此采用此种方法可以制成各种极微细的高硬度(金刚石烧结体和硬质合金)工具、复杂形状的模具和工件,为此受到业界的普遍关注。 相似文献
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用实验的方法研究电火花微细加工中放电能量在极间的分配和对电极损耗的影响,并研究式具电极材料和工件材料对电极损耗的影响,实验表明,从减小电极损耗,增加有用功率出发,电火花微细加工应使用微能窄脉冲电源。 相似文献
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Increasing demand on precision machining using computerized numerical control (CNC) machines have necessitated that the tool
move not only with the smallest possible position error but also with smoothly varying feedrates in 3-dimensional (3D) space.
This paper presents the simultaneous 3D machining process investigated using a retrofitted PC-NC milling machine. To achieve
the simultaneous 3-axis motions, a new precision interpolation algorithm for 3D Non-Uniform Rational B-Spline (NURBS) curve
is proposed. With this accurate and efficient algorithm for the generation of complex 3D shapes, a real-time NURBS interpolator
was developed using a PC and the simultaneous 3D machining was accomplished satisfactorily. 相似文献
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针对模具电极加工的智能编程问题,研究基于Edgecam软件的自动化程序编制方法。首先,在基于Edgecam的基础上提出了电极智能化编程算法,而后,论述了特征识别、数据库连接、界面设计和特征编程等关键技术,利用PCI和PDI等二次开发语言编制了程序,最后以某企业的电极加工的实例证明了方法的有效性,实现了制造的智能化和快速化,为其他产品的智能编程提供了借鉴。 相似文献
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Adopting the sidewall-insulated hollow electrode (SIHE) is an ideal approach to achieve electrolyte-refresh and stray corrosion inhibition functions in micro electrochemical machining (ECM) processes. Most of the traditional SIHEs are made of metal substrate and non-metal thin films. The insulating film has poor durability, and the preparation approach of the traditional SIHE is complex and has limited repeatability. This research presents a novel structure of a SIHE with an insulated substrate and an internal conductive film. The machining performance of the novel SIHE is primarily verified by a potential distribution analysis in the numerical simulation. According to the concept of the novel SIHE, a silver-plated glass tube electrode (SPGTE) is presented: the glass tube acts as the insulated substrate, and the plated silver layer acts as the working cathode. Then, a fabrication process for the SPGTE is proposed. Silver layers are tightly bonded on the glass tube surface by electroless plating. The thickness of the silver layer is approximately 3.5 μm, and its electrical resistivity is approximately 5 × 10−5 Ω cm. In micro ECM experiments, microstructures with steep sidewalls with taper angles of <5° are machined, which is attributed to the stray corrosion inhibition of the insulated substrate. Micro holes with an aspect ratio of approximately 3 are machined. There is no accumulation of electrolytic products and short circuits, which verifies the excellent electrolyte-fresh performance. Compared with the traditional SIHEs, the novel SIHE could provide a simpler and more reliable way of fabricating sidewall-insulated electrodes. The proposed electrode structure can further inspire new electrode preparation schemes based on new substrate materials and film preparation approaches. 相似文献
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