电火花线切割加工表面微织构技术研究

表面微织构加工是一个相当复杂的过程,涉及微织构的尺寸、质量及形貌等问题。为解决制备微织构存在的问题,利用数控电火花线切割加工技术,在45钢表面加工微槽织构,研究线切割制备微织构的尺寸、形貌。试验分别采用钼丝、铜丝作为电极丝,设计脉宽、脉停、电流等线切割正交试验,切割宽度小于400μm的微槽织构,分析不同线切割参数、电极丝材料对微槽尺寸精度和微槽切口处光整度的影响。通过采集、测量试验所得工件表面微槽织构,发现线切割参数对微槽尺寸精度和切口处光整度有较大的影响;在较小线切割参数下,钼丝切割的微槽尺寸大于铜丝,在较大的线切割参数下,铜丝切割的微槽尺寸大于钼丝;对比微槽切口处光整度,发现钼丝切割的微槽整体质量优于铜丝。试验列出不同线切割参数切割的微槽尺寸,为电火花线切割加工微织构提供了试验数据。

Research on Surface Micro texture Technology of WEDM

The fabrication of surface micro textures is a rather complex process,involving size,quality and morphology of microtexture.In order to solve problems of fabricating micro textures,microgroove texture was fabricated on 45 steel surface by numerical control WEDM technology.The size and morphology of the micro textures fabricated by WEDM were studied.The orthogonal experiments of pulse width,pulse stop and current were designed by using molybdenum wire and copper wire as electrode wires respectively.The microgroove textures with cutting width less than 400μm were cut.The effects of different wire cutting parameters and electrode wire materials on the microgroove sizes accuracy and the smoothness of the microgroove incisions were analyzed.Through collecting and measuring the microgroove textures on the workpiece surface,it is found that wire cutting parameters have a great influence on the microgroove sizes accuracy and the smoothness of the incisions.Under smaller wire cutting parameters,the microgroove sizes of molybdenum wire cutting are larger than that of copper wire cutting;under larger wire cutting parameters,the microgroove sizes of copper wire cutting are larger than that of molybdenum wire cutting.The overall quality of the groove cut by molybdenum wire is better than that of copper wire.The microgroove sizes of different WEDM parameters are listed in the experiment,which provides experimental data for WEDM micro textures processing.