复合材料电极微细电火花加工表面微沟槽结构

Micro-EDM of Micro-groove Structure by Using Composite Micro-electrode

表面微沟槽结构广泛应用于国防、电池反应堆、集成电路等领域。由Cu箔、CuSn合金箔和Sn箔三类材料构成的Cu-Sn复合材料微电极,可在工件表面获得具有复杂断面轮廓的微沟槽,故提出了Cu-Sn复合材料微电极的制备工艺并将其应用于表面微沟槽结构的微细电火花加工,建立了复合材料微电极的损耗模型,通过实验分析了复合材料微电极电火花磨削成形的过程。以上述研究为基础,采用厚度0.1 mm的Cu箔、厚度0.1 mm的均质CuSn合金箔和厚度0.3 mm的Sn箔制备复合材料微电极,并在180 V加工电压、26μs脉冲宽度和11μs脉冲间隔的作用下,对复合材料微电极进行电火花磨削成形并将其应用于Ti-6Al-4V的微细电火花加工。结果表明:Ti-6Al-4V表面获得了两种类型的微沟槽阵列结构,从而验证了所提工艺的可行性。

The preparation process of Cu-Sn composite micro-electrode was proposed and applied it in the micro-EDM of micro-groove structure.Cu-Sn composite micro-electrode was composed of Cu foil,CuSn alloy foil and Sn foil.By applying composite micro-electrode in micro-EDM,the different areas of the micro-electrode had the different EDM wear,which can fabricate micro-groove with complex profile shape on the workpiece surface.The wear model of composite micro-electrode was established,and the forming process of composite micro-electrode was analyzed by experiment.Based on the above research,the composite micro-electrode was prepared by using 0.1 mm-thickness Cu foil,0.1 mm-thickness homogeneous CuSn alloy and 0.3 mm-thickness Sn foil.Finally,under the effect of 180 V processing voltage,26μs pulse width and 11μs pulse interval,the composite micro-electrode was grinding formed by EDM wear and then applied it in the micro-EDM of Ti-6Al-4V.The experimental results showed that two types of micro-groove array structures were obtained on Ti-6Al-4 V surface,which verified the feasibility of the proposed process.