基于微PCD刀具的微结构成型制造与应用

Fabrication and Application of Micro Structures Utilizing Micro PCD Tools

本文提出一种基于微聚晶金刚石(PCD)刀具的微结构快速车削成型制造方法.首先利用电火花线切割加工(WEDM)放电蚀除技术实现了微PCD刀具的精密切割成型制造.在WEDM过程中对线切割丝的运动轨迹、电火花加工间隙及加工能量进行了研究分析以提高微切削刀具的制造精度.随后将微PCD刀具安装到精密车削系统,通过铝合金的微车削实验验证了本文所提出的微结构快速成型制造方法的可行性.最后对微刀具的磨损形态进行了实验分析.在微车削过程中,刀具切削刃无明显磨损和破坏,而工件材料粘结于刀具前刀面是造成微结构加工精度降低的主要因素.本文所提出的微细制造技术有望成为微结构快速、大批量生产的潜在工业应用.

This paper studied the fast generation of micro structures by means of micro polycrystalline diamond （PCD） tools, which were fabricated by applying the wire-cut electrical discharge machining （WEDM） technology. Firstly, the machining performance of the micro PCD tools fabrication was investi-gated in the WEDM process. In order to improve the accuracy of the fabricated tool shape, the motion path of the cutting wire, the sparking gap and the discharging energy were explored. Then, by applying the micro PCD tools which were installed in a precision turning system, micro structures were directly fab- ricated on the alumina alloy workpiece with just a simple micro turning process, which verifies the feasi- bility of the proposed microfabrication method. Finally, the micro tool wear was also investigated, and there was no considerable tool shape deterioration or tool edge damage in the micro turning process. How- ever, the adhesion of the workpiece material to the tool cutting edge is one of the reasons to cause the ma- chining accuracy decrease. The proposed microfabrication process is expected to become a potential meth- od for the fast generation and mass production of micro structures in practical industrial applications.