电火花加工电极的复合制造技术

利用电铸和等离子喷涂两种工艺,制造电火花加工用精细复杂电极,是一种经济、快速和有效的方法,以车灯反光镜模具电极为例,介绍了该工艺的实施过程。结果表明,所制造的电火花电极不但精度高,而且周期短,成本也大大下降。     

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。     

一种深腔异形底面高精度复杂沉窝电火花加工技术研究

针对壳体底部均布三处复杂沉窝加工难题,通过分析沉窝结构特点,采取提高电极制造精度、优化电火花加工工艺参数、降低电极损耗、提高电极和工件的安装定位精度等措施,实现了复杂沉窝的电火花精密加工。     

基于6自由度串联机器人的电火花铣削加工轨迹规划及伺服控制策略研究

针对传统电火花铣削加工所存在的灵活性不足和被加工工件尺寸受限等问题，提出了基于6自由度串联机器人的电火花铣削加工方法。基于四元数理论建立了工具电极复杂轨迹规划方法，实现了工具电极变姿态铣削加工。为了解决串联机器人无法满足电火花加工对放电间隙实时调整的快速响应要求，提出了工具电极垂直轨迹回退的伺服控制策略，实现了对加工间隙的快速调整。利用机器人的3个自由度和6个自由度分别开展了工具电极定姿态和变姿态下的电火花铣削加工实验，实验结果表明当工具电极变姿态时，加工过程中工具电极端部与工件表面发生放电，铣削加工轨迹的槽宽略大于工具电极直径，因此工具电极变姿态电火花铣削加工曲面工件时精度和效率更高。最后，在半球形工件上实现了电火花铣削加工三种复杂轨迹，验证了基于6自由度串联机器人电火花铣削加工技术的可行性和有效性，具有很大的市场应用潜力。     

电火花加工（EDM）中所用电极的制造方法

电火花加工（ＥＤＭ）用的电极的曲型制造方法是车削和铣削，也有用数控方法来加工的，但是，对于内部结构复杂的电极，用这些方法往往很难达到要求，本文将介绍几种用激光快速成型（ＲＰ）技术制作电极的方法。     

CNC电火花铣削加工试验研究

对于复杂的成型模具,传统的电火花加工（ＥＤＭ）必须首先制造出复杂的成型工具电极,然后在机床上向下进给加工出工件。而本文介绍了一台三轴ＣＮＣ电火花铣销加工试验设备,它能象ＣＮＣ立式铣床一样使用简单的指状工具电极加工成型表面,我们使用固定的和旋转指状电极进行了加工实验,并对结果进行分析讨论。     

基于分层制造原理的微细电火花加工技术研究

结合快速原型制造中的分层制造概念及电火花加工中的电极等损耗概念，提出了利用简单形状电极的基于分层制造原理的微细电火花加工技术。系统地研究了该方法的基本原理与实现方案，就加工中的电极损耗及其补偿策略、电极运动轨迹的规划等关键技术进行了深入的研究，并用该方法制作出了具有４０管脚的集成电路芯片插座模具及三维曲面。试验表明：该方法具有加工范围广、加工精度高和加工成本低等特点，具有良好的应用潜力。     

微细小孔电火花加工用工具电极的制造

电火花加工在小孔加工中常被采用。但加工电极的制作十分费时,有时,高达实际加工小孔时间的数十倍至数百倍,而电火花加工的电极损耗又不可避免。为此,在实际生产中,因加工费用太贵而不被采用。本文就常用的小孔电极制造方法作了介绍和讨论,并推荐了一种较为先进的精密电极的快速制作方法。     

《特种加工》学习指导──电火花成型加工

电火花加工技术是本世纪五十年代发展起来的,在理论和实践方面一直在不断的提高、发展与完善过程中。电火花加工理论上的完善促进了技术的前进,而生产技术的发展又促使理论上的进一步完善。因此,学习过程中要有发展的观点,辩证的观点。现就电火花成型加工一章中的几个问题的学习作一介绍。 一、电火花加工中的电极损耗 电火花成型加工是电极对工件的复制过程,由于存在着电极的损耗,从而使加工精度受到影响,而且大大增加了工具电极的制造工作量。因而降低电极损耗一直是人们关心的一个问题。 电火花加工过程是一个微观的极为复杂的电物理过程…     

电火花加工微细孔

微细孔的电火花加工中,工具电极的制造非常关键而又困难。本文就目前一种较为先进的精密电极的制造工艺进行了试探,并以制得的微细电极进行了微细孔的电火花加工实验。     

EDM electrode manufacturing using RP combining electroless plating with electroforming

This study investigates an effective method for manufacturing electrical discharge machining (EDM) electrodes using the rapid prototyping (RP) system based on electroless plating (nickel plating) and electroforming (copper). This method was shown to finish the development of die-sinking electrical discharge machining (EDM) electrodes, shorten the electrode manufacturing process, decrease the manufacturing duration as well as the cost of electrodes. The electrode prototype was drawn with Pro/E 3D CAD, and the CAD model was then transformed into the stereo lithography (STL) file format. A Zcorp 402 3DP rapid prototyping machine was adopted to make a gypsum powder electrode prototype with a complex appearance. The gypsum material is sealed by resin permeation, enhancing its water-resistance and strength. Electroless plating was then performed to introduce electric conductivity onto the gypsum electrode surface, followed by copper electroforming of the thickness about 1 mm to obtain the EDM electrode. Furthermore, die-sinking electric discharge machining was performed. Test results indicate that no crack was found on the electrode and that the electrical discharge machining effects are promising.     

The Potential of Plating Techniques in the Development of Rapid EDM Tooling

Electrodischarge machining (EDM) is a widely used process in the manufacturing of mould cavities for plastic products. EDM work typically accounts for a large portion of overall production time. A major cost and time element of EDM is electrode production, which can account for more than 50% of the total machining costs. A large complex electrode profile, which is very difficult to produce through machining and is also time consuming, can be easily produced using the rapid prototyping (RP) technique. The direct laser sintering of metal powders is a widely established RP process that can be employed for the rapid production of EDM electrodes. In this study, the above-mentioned technique has been employed. The powder mixture used in this process consists of copper, tin, nickel and phosphorus. An infra-red (IR) 200 W CO2 laser is used to sinter the powdered metals layer-by-layer in order to form solid electrodes. Electroless copper and copper plating are then employed to improve the surface finishing and the conductivity of the sintered electrode as it deposits a uniform thickness of metal onto the substrate by chemical reaction, without building up at the edges and corners, and achieves unique physical characteristics. The performance of the newly developed electrode is very similar to that of conventional copper electrodes. It is found that integration of RP and electroless plating techniques can be a potential means of the rapid production of EDM electrodes at low cost.     

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。     

模具模腔的一种快速制造方法

在快速成型技术的一个重要分支——选择性激光烧结的基础上 ,详细介绍了选择性激光烧结技术与电火花加工技术和粉末冶金中的金属熔渗技术相结合 ,制作三维复杂模具模腔的工艺方法 ,同时给出了一个典型加工实例     

Development and application of new composite materials as EDM electrodes manufactured via selective laser sintering

The cost of a part manufactured by electrical dischargeEDM machining (EDM) is mainly determined by electrode cost. The production of electrodes by conventional machining processes is complex, time consuming, and can account for over 50 % of the total EDM process costs. The emerging additive manufacturing (AM) technologies provide the possibility of direct fabrication of EDM electrodes. Selective laser sintering (SLS) is an alternative AM technique because it has the possibility to directly produce functional components, reducing the tool-room lead time and total EDM costs. The main difficulty of manufacturing an EDM electrode using SLS is the selection of an appropriate material, once both processes require different material properties. The current work focused on the investigation of appropriate materials that fulfill EDM and SLS process demands. Three new metal-matrix materials composed of Mo–CuNi, TiB₂–CuNi, and ZrB₂–CuNi were developed and characterized. Electrodes under adequate SLS conditions were manufactured through a systematic methodology. EDM experiments using different discharge energies were carried out, and the performance evaluated in terms of material removal rate and volumetric relative wear. The results showed that the powder systems composed of Mo–CuNi, TiB₂–CuNi, and ZrB₂–CuNi revealed to be successfully processed by SLS, and the EDM experiments demonstrated that the new composite electrodes are promising materials. The work also suggests important topics for future research work on this field.     

电极材料对电火花加工质量影响的分析

对电火花加工中电极材料的合理选取作了详细的分析和探讨，并用实验结果分析了电极材料性能对加工质量的影响，说明了电极材料是影响电火花加工质量的一个重要因素。     

新型蠕动式微细电火花加工机构

阐述了小型微细电火花加工机构的研究现状。针对现在遇到的主要问题,设计开发了一种新型的管状结构蠕动式微细电火花加工机构。介绍了该新型机构的原理和实现方式,并对其主要部件进行了理论建模和有限元分析。该新型机构能够对微细电极进行较为有效精确的夹持和定位,响应速度较高,其结构对称,紧凑可靠,可以实现从任意方位任意角度进行加工,有较高的实用价值。     

新型蠕动式微细电火花加工装置的设计开发

首先概括阐述了小型化微细电火花加工机构的研究现状。在此基础上,针对现在遇到的主要问题,设计开发了一种新型的管状结构蠕动式微细电火花加工机构,能够对微细电极进行较为有效精确的夹持和定位,响应速度较高。介绍了该新型机构的原理和实现方式,并对其主要部件进行了理论建模和有限元分析。该机构可以实现从任意方位任意角度进行加工,结构对称,紧凑可靠,有较高的实用价值。     

电火花摆碾加工的原理及装置设计

用传统电火花加工硬质合金刀片时,需要事先制作成形电极,加工成本高且加工质量较差,因此提出一种新的加工方法—电火花摆碾加工。电火花摆碾加工通过控制普通电极的旋转和摆动来加工出特定形状的锥形孔,具有加工效率高、加工质量好、节省成形电极制作时间和成本等优点。为进行初步试验,在现有加工设备基础上设计了一套电火花摆碾加工装置,包括电极自转摆角装置、工件回转装置以及控制系统三个部分。设计的夹具可实现三角刀片的自动定心及快速装夹。     

一种简易的电火花专用夹具

介绍了一种简易的电火花专用夹具。该专用夹具结构简单,使用方便,可提高生产效率,节约电极材料,在模具加工中广泛使用。