微幅往复走丝微细电解线切割试验研究

Wire Electrode Micro-electrochemical Machining with Tool Micro-amplitude Reciprocating Motion

微细电解线切割是一种新型的微细加工技术,适合高精度金属窄缝、窄槽等微细结构的加工,由于加工间隙内电解产物排出困难,容易影响加工精度。为了提高产物排出效率,提出线电极微幅往复走丝促进加工间隙内电解产物排出的方法,改善了加工稳定性,提高了加工精度和加工效率。建立了间隙内电解产物排出效率对加工精度、加工速度影响的数学模型,分析了线电极走丝速度和走丝幅值对间隙内电解产物排出和电解液更新的影响。通过试验研究了线电极的走丝速度和走丝幅值对加工精度和加工效率的影响规律,采用优化参数在厚度为80μm的钴基弹性合金上进行微槽结构加工,底面粗糙度约为0.45μm,倒角半径小于8μm。结果表明线电极轴向微幅往复走丝可以有效地提高加工质量和加工效率。

Products of electrolysis in the inter-electrode gap is one of the major factors influencing wire electrode micro-electrochemical machining precision. To enhance the efficiency of removing these products, a new method is proposed that allows the wire electrode to perform micro-amplitude reciprocating movement in the axial direction during the processing. The machining stability and accuracy can thus be improved and the machining efficiency is increased. A mathematical model is built to investigate the influence of the wire electrode travelling speed and micro-amplitude on removing the product and refreshing the electrolyte, Their effects of the electrode travelling speed and micro-amplitude on the machining accuracy and efficiency are investigated experimentally. A micro groove on an alloy is generated with the optimized parameters with a resulting surface roughness of about 0.45 IJm and radius of chamfer is lesser than 8 μm.