聚晶金刚石复合片电火花线切割加工电极丝损耗研究

Study on Electrode Wire Wear during WEDM Processes by PDC

采用电火花线切割方法对聚晶金刚石复合片(PDC)进行了线切割加工实验,利用带能谱分析的扫描电子显微镜(SEM)观察了电极丝表面的显微形貌。从微观角度研究了PDC超硬材料电火花线切割加工的电极丝损耗机理,探讨了电参数和冲液条件等因素对电极丝损耗的影响。实验研究发现,采用贴附式高压喷液方式在高电压、小脉宽、大峰值电流的加工条件下,PDC切割效率为19.35mm^2/min,电极丝损耗为1.5~2μm(10~4 mm^2切割量),较常压喷液方式切割效率提高51.6%,丝损降低15.2%。

The authors carried out the wire cutting machining experiments of PDC using WEDM,and observed the surface micro morphology of wire electrode with the SEM which might analyze the energy spectrum. The electrode wire wear mechanism of PDC ultra hard material was studied from the microscopic points of view, and the influences of the electrical parameters and the conditions of the washing liquid on the wire wear were discussed. It is found that the attached type high pressure liquid spraying mode, in the processing conditions of high voltage, small pulse width, high peak current, PDC cutting efficiency is as 19.35 mm^2/min,the electrode wire wear is as 1.5-2μm （for 10^4 mm^2 cutting volume）. The cutting efficiency is increased by 51.6% compared with the normal pressure liquid injection method, and the reduction of the wire wear by 15.2%.