CN101115580A - Composite wire for electrical discharge machining - Google Patents
Composite wire for electrical discharge machining Download PDFInfo
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- CN101115580A CN101115580A CNA2006800045646A CN200680004564A CN101115580A CN 101115580 A CN101115580 A CN 101115580A CN A2006800045646 A CNA2006800045646 A CN A2006800045646A CN 200680004564 A CN200680004564 A CN 200680004564A CN 101115580 A CN101115580 A CN 101115580A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23H—WORKING OF METAL BY THE ACTION OF A HIGH CONCENTRATION OF ELECTRIC CURRENT ON A WORKPIECE USING AN ELECTRODE WHICH TAKES THE PLACE OF A TOOL; SUCH WORKING COMBINED WITH OTHER FORMS OF WORKING OF METAL
- B23H7/00—Processes or apparatus applicable to both electrical discharge machining and electrochemical machining
- B23H7/02—Wire-cutting
- B23H7/08—Wire electrodes
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Abstract
The invention relates to a wire (1) which comprises a copper or pinchbeck core (2) surrounded by a pinchbeck coating consisting of a continuous pinchbeck sub-layer (3) in phase ss and a superficial layer (4) with a fractured pinchbeck structure in phase enabling the appearance of pinchbeck in phase ss in the fractures (5a). In this way, the electrical discharge machining speed is essentially increased.
Description
Technical field
The present invention relates to be used for coming by spark machined the wire electrode of cutting metal or conductive material at the electrical discharge machining (EDM) machine.
Background technology
Most of modern EDM machines all are designed so that with ultimate tensile strength at 400～1000N/mm
2Between diameter be roughly the naked brass wire of 0.25mm.
The EDM silk should conduct electricity.They are worked by corrode discharge between this silk thread and electrically conductive workpiece in controlled water base dielectric.
In order to realize accurate processing, especially, must use minor diameter silk thread with high limit tensile strength in order to cut bight with minor radius, make them can in machining area, keep the amplitude of tensioning and constrained vibration.Therefore, the silk thread that people are formed from steel in the middle part of may attempting to use at least is to increase ultimate tensile strength.
Because spark machined is slower process, therefore there is the maximized demand of especially roughing speed of process velocity that makes simultaneously.In present patent application, roughing speed is with mm
2/ min just measures with the amplification speed of cutting face area, perhaps promptly measures according to the speed that silk thread penetrates workpiece with mm/min for the assigned altitute of workpiece.Should be understood that this speed directly depends on the discharge energy that discharges in the machining area between silk thread and the workpiece, thereby depend on that silk thread can be transmitted to the electric energy in the machining area.Yet the Joule heat that the corrosion discharge in machining area and the electric current of process silk thread produce tends to make the silk thread heating.
A restriction that is used for the silk thread of spark machined is that silk thread can rupture under the synergy of heat and mechanical tension.This makes the user have to limit the working power of its EDM machine, especially when silk thread can't be cooled off particularly well, during for example in taper processing or at the workpiece that processing is grown very much.
The straightforward procedure of avoiding rupturing is to use the major diameter silk thread, for example uses the silk thread of diameter more than 0.30mm.Yet this will limit the least radius of machinable re-entrant angle.
Proposed to use galvanized wire, compared with naked brass wire, the effect of coating has increased process velocity.Yet pure zinc layer is quick-wearing and can not enough protect the silk thread core with cutting farm labourer part for a long time very.
Propose to use the brass of about 47% zinc of beta-brass layer-promptly contain to cover the silk thread core, thereby avoided the shortcoming of the superficial layer rapid wear that pure zinc makes.Thereby can strengthen cutting ability.
Document US 4,977,303 have illustrated a kind of method and a kind of wire electrode with special construction that is used to make wire electrode.
Description and claimed method comprise in the document: for example be made of copper metal-cored is provided; cover with the volatile metal layer such as zinc of given thickness (13-15 μ m) that this is metal-cored; under oxidizing atmosphere with its whole being heated to more than 700 ℃; preferably be heated to more than 850 ℃; so that zinc and copper diffusion are about three times diffusion layers of the given thickness of initial zinc layer until obtaining thickness, and the thickness of this diffusion layer is reduced by at least 30%.After thickness reduced 30%, the operating condition that is used for this method must cause about 33% zinc concentration at diffusion layer, promptly causes α-copper/kirsite of the about 22 μ m of thickness.
Description and claimed wire electrode comprise that thickness is the surface oxide layer of about 1 μ m in the document; this surface oxide layer cladding thickness is approximately 6 μ m, (the being γ-copper/kirsite) pantostrat that contains the copper/kirsite of 58-60% zinc, and zinc concentration then reduces the degree of depth until about 11 μ m towards core.The undeclared wire electrode that how to obtain this γ of having-copper/zinc alloy layer of the document.
Recently, document US 5,945,010 proposes to make zinc-plated alpha-brass annealing, so that form γ-brass perisphere, the blank to such acquisition carries out wire drawing so that it reaches final diameter then.Wire-drawing operation produces the γ-brass surfaces layer of fracture.The document is mentioned, and the fracture of superficial layer can't reduce the cutting speed performance.In addition, the document does not advocate to be provided with the beta-brass layer.
At last, document US 6,781,081 (perhaps US 2003/0057189 A1) discloses a kind of well behaved silk thread, and this silk thread is superimposed with two continuous layer of brass on the metal core, and internal layer is made by beta-brass, and continuous skin is made by γ-brass.The speed of EDM thereby be higher than the silk thread that only has γ-layer of brass or beta-brass layer.Yet how the document undeclared makes such silk thread if being.
Summary of the invention
For given processing electric current, need process as quickly as possible, and also need to use the highest as far as possible processing electric current for given silk thread (wire, wire electrode) diameter.
The present invention is derived from such surprising discovery, promptly, for having the metal-cored EDM silk thread that is coated with alloy-layer, by coating (coating is set on the core of making by copper or brass, cover layer) still can make the performance of EDM obtain appreciable enhancing, described coating combines the γ-brass surfaces layer and the beta-brass sublayer of fracture.Document US 5,945 has been overthrown in this discovery, 010 instruction, and the document thinks that if use the γ-brass surfaces layer of fracture, then cutting speed does not have any raising, and the document does not especially advocate to use beta-brass.
Therefore, in order further to improve the EDM process velocity, the present invention proposes a kind of wire electrode that is used for spark machined, and this wire electrode comprises:
-the core made by copper, copper alloy or brass;
-Brass coating,
Wherein, this Brass coating comprises stacked:
-beta brass sublayer; And
-have a superficial layer of γ-chalocopyrite structure of locating to expose the fracture of beta-brass at crackle (fracture portion).
According to favourable embodiment of the present invention, beta-brass is filled the crackle in γ-brass surfaces layer at least partly.
Advantageously, described beta-brass sublayer can be continuous, thereby provides better effect than discontinuous sublayer.
The thickness of the γ-brass surfaces layer by making fracture is less than 8% of wire electrode diameter, preferably less than the wire electrode diameter 5% and obtain better effect, this effect comprises that EDM has higher speed and processed workpiece has better surface smoothness.If thickness is about 5% greater than the wire electrode diameter, can find that then the surface smoothness of processed workpiece descends: the finished product workpiece after the processing has the streak parallel with the direction of the wire electrode of finishing processing.
Scheme or additional project as an alternative, the thickness that advantageously makes described beta-brass sublayer is in 5%～12% scope of wire electrode diameter.
As about 10% time less than the wire electrode diameter of the γ-brass surfaces layer of fracture and the combination thickness of beta-brass sublayer, can make the industrial-scale production of such wire electrode easier.Surpass this value, wire electrode can rupture in the drawing step manufacture process.
A kind of favourable embodiment is that about 6% the beta-brass sublayer that the γ-brass surfaces layer of about 2% fracture that thickness is the wire electrode diameter and thickness are the wire electrode diameter is set.
If the γ-outer surface of brass surfaces layer is oxidized to the color (dark color) of obfuscation fully, then also can make EDM speed obtain to increase.
In some EDM machine, disadvantage is that oxide may increase the difficulty that electrically contacts, and perhaps causes electric conductor to wear and tear too early.Therefore, preferably make the degree of oxidation of outer surface of γ-brass surfaces layer lower, and still for example have can catoptrical bright appearance, so that compatible with the EDM machine that utilizes this Characteristics Detection wire electrode to exist.
In fact, for fear of electrically contacting the performance of also guaranteeing to strengthen EDM with the electric wire wear problem simultaneously, can preferably such wire electrode, in this wire electrode, the average thickness that decomposes the oxide layer that (dissolving) measure by selectivity at about 100nm between about 250nm, and preferably less than 200nm.This oxide layer mainly is made of zinc oxide.
Can preferably select to make core by zinc content less than 40% brass, the brass of more preferably selecting to contain 20% zinc is made core.
As possibility, can select the core that is made of copper, so that electric conductivity the best of wire electrode.
Also can increase the speed of EDM by the core that the CuZn37 alloy of selecting to contain 37% zinc is made, this also has the attendant advantages that reduces production costs.
Can confirm, advantageously polydisc silk thread in batch be executed and carried out low temperature diffusion and make such wire electrode, save energy because compare this mode with high temperature and/or online processing.
Therefore, according on the other hand, the present invention proposes a kind of method that is used to make the kind electrode silk of economy, this method may further comprise the steps:
A) provide the core of making by copper or brass;
B) utilize electrolytic method to cover described core, to form pre-blank with the zinc layer;
When c) needing, described pre-blank is carried out first wire-drawing operation so that the smooth surface of galvanized wire, and thereby make this silk thread after spreading, be easy to lay out;
D) in stove, carry out 2 hours to about 40 hours annealing to the about 400 ℃ temperature pre-blank after to wire drawing with about 200 ℃, select time and temperature, make and make blank by the copper of tectal zinc and core or the diffusion between the brass, this blank has beta-brass sublayer and γ-brass surfaces layer, this γ-brass surfaces layer this in the surface at least by slight oxidation;
E) blank that such diffusion is obtained carries out the second cold drawn silk operation, so that this blank forms final diameter and makes γ-brass surfaces fault rupture.
Yet, also can be by also continuing the batch heat treatment of longer time makes the kind electrode silk at low temperatures, as long as the duration meets industrial requirements.On the contrary, can utilize at Wiring technology manufacturing kind electrode silk by when taking out wire electrode, being heated higher temperature (about 600 ℃).
In the second wire-drawing operation process, outside γ at first fragments into mutually surperficial equally distributed of wire electrode.Between these pieces, has the sky crackle.Then, still in the wire-drawing operation process, these pieces reassociate together along the longitudinal direction, thus allow β phase sublayer from passing between them so that final surperficial concordant at ad-hoc location and wire electrode.
As a reference, the diameter reduction that realizes of second wire-drawing operation about 40% to about 78% scope.This can suitably rupture the perisphere of γ-brass.
In addition, first wire-drawing operation can be carried out to and make diameter reduce about 40% to about 60%.
In the method, annealing steps d advantageously) carry out in stove with such temperature and time, this temperature and time is selected such that after step e) the average thickness that decomposes the oxide layer on the wire electrode that measures by selectivity is at about 100nm with approximately in the scope of 250nm.
It is impossible listing the free and temperature conditions of the institute that can produce certain disperse state simply.This be because the diffusion carried out in order to make the spark machined silk thread to relate to both out-of-flatnesses also thin or thick in the outer zinc layer that is enough to constitute the semo-infinite medium.In addition, latent heat path (time dependent temperature) is very different.
In air, carry out under the situation of dispersion operation at copper wire or zinc-plated CuZn20 brass wire to 4kg dish packing, the thickness e of having found β phase intermediate layer increases according to the function of following law as time t: de/dt=D/e, D is the diffusion coefficient that depends on the composition of temperature T and silk thread core, and de/dt is the derivative of thickness e about time t.Coefficient D be temperature T according to normalized form D=D
0e
-Q/RTFunction, D
0Be to use m
2The frequency factor that/s represents, Q are the activation energy of representing with J/mol, and R is the perfect gas mol gas constant and equals 8.31J/ (mol.K) that T is the temperature of representing with absolute temperature.
D
0Depend on the characteristic of the core of zinc-plated silk thread with Q.For in about 620 ℃ of temperature that arrive in about 680 ℃ of scopes, can be that the copper core is selected D
0=4.98 * 10
-4And Q=129500, and be that CuZn20 brass core is selected D
0=2.64 * 10
-6And Q=100800.
For the CuZn37 core, can select D
0=4.10 * 10
-3And Q=138200.
Can use any known method that differential formulas de/de=D/e is carried out integration.Under steady temperature, integration satisfies formula of reduction e=(2Dt)
1/2Final β phase thickness must be subjected to available zinc quantitative limitation, and according to the present invention, leaves less γ phase in the surface.
For the dispersion operation of carrying out on the silk thread in being packaged in big reel, advantageously evenly extend the processing time with the bulk temperature of guaranteeing reel by reducing soaking temperature.
Like this, the present invention can obtain some β phases at the α of core with the γ of outside mutually according to following steps between the layer: adopt the silk thread of the pure spelter coating that comprises the brass core that contains 63% bronze medal and 37% zinc and 3 μ m, the external diameter of this silk thread is 0.46mm; With 220 ℃ to this silk thread heat treatment 15 hours.Thereby be that the γ of about 4 μ m forms the β phase sublayer that thickness is approximately 2 μ m mutually between the skin at α phase core and thickness.
More than given information make those skilled in the art in fact can be exactly to select its hot path according to the final condition select time and the temperature conditions of primary condition and expectation.
To spread on the silk thread of oxygen be very important being exposed to, and this is because be not inert gas atmosphere or be not that significant volatilization can appear in zinc under the situation of the pressure that reduces, thereby remaining β phase thickness can be low especially when diffusion finishes.
If expect the outer surface of strong oxidation γ-brass surfaces layer, then in air, anneal.This air needs can be than the desired surface that is diffused into silk thread quickly of the oxidation of silk thread.In order to realize this point, the pre-blank of intensive coiling not for example is placed in the basket thing, perhaps, use less than 0.5 ℃/min-for example the shallow thermograde of 0.2 ℃/min temperature is risen.Intensive if reel, then mainly be that the outside of reel is oxidized, and the inboard does not also contact with oxygen.
If the outer surface oxidation of expectation γ-brass surfaces layer is very little, then can utilize the air that exists between the silk thread thigh self., reel can be encapsulated in the device of sealing or semitight, for example around silk thread parcel thin metal foil, for example aluminium foil for this reason.Wrap device must make the air that is contained in the parcel during heating treatment can and wherein expand around reel and shrink.Therefore, by limiting oxidation in the parcel that pre-blank is wrapped in sealing or semitight.
The temperature and time condition that is used to spread heating steps be preferably selected to the average thickness that makes after step e) by decomposing the oxide layer that measures in selectivity on the wire electrode at about 100nm to the scope of about 250nm.
The solution that described selectivity is decomposed can be following solution: contain 50ml one mole of acetic acid in 200ml water, wherein be added with the 0.5ml propargyl alcohol.About 2 minutes of immersion time.The measurement diameter is D
1The loss in weight M of length L of silk thread.Suppose that this loss in weight M is because the dissolving of zinc oxide causes the density M of this zinc oxide
VBe approximately 5600kg/m
3Thereby can utilize formula E
0=M/ π D
1LM
VRelease oxide thickness E
0
Therefore be not recommended in the inert atmosphere or under the pressure that reduces and spread, because zinc can partly volatilize from the surface of silk thread and form powder.This have highly active metal dust and do not expect that why Here it is is recommended in the air spreads.
Description of drawings
To more know other purpose of the present invention, feature and advantage from the description of the following specific embodiment that provides with reference to accompanying drawing, in the accompanying drawings:
Fig. 1 is the perspective schematic view according to the EDM silk of one embodiment of the present invention;
Fig. 2 is the schematic cross sectional views of magnification ratio of the EDM silk of Fig. 1;
Fig. 3 is the longitudinal cross-section of passing according to the EDM silk with brass core of one embodiment of the present invention; And
Fig. 4 passes the cutaway view that has the EDM silk of copper core according to of the present invention.
The specific embodiment
In embodiment shown in the drawings, the wire electrode 1 that is used for EDM processing comprises the core of being made by copper or brass 2, this core 2 is coated with the coating that is made of continuous beta-brass sublayer 3 and superficial layer 4, and this superficial layer 4 has the γ-chalocopyrite structure that exposes the fracture of beta-brass in cracks.
In this specification and claims, use term " beta-brass " to represent to contain to have an appointment the ormolu of 45% to 49% zinc.At ambient temperature, this β is rule mutually and has certain fragility, and is commonly called β ' phase.If surpass uniform temperature, structure then becomes irregular, so be called the β phase.Transformation between β and the β ' phase is inevitable, but its influence is very little.Thereby for simplicity, in this manual, this brass is only represented by single term " beta-brass ".
In specification and claims, use " γ-brass " to represent that the ratio of zinc accounts for about 65% ormolu.
The zinc content of " alpha-brass " can be less than 40%, for example, and less than about 35% or even less than about 20%.
As for superficial layer 4, for example can distinguish γ alpha region 5 (Fig. 3), this zone 5 is the border with the crackle 5a that wherein exposes beta-brass.
Beta-brass can be filled the crackle 5a in γ-brass surfaces layer 4 at least partly, thereby makes the surface of silk thread have to a certain degree continuity.
The advantageous effects of such silk thread structure is confirmed by several tests that the silk thread to different structure carries out.
Test one
This first test confirms, the γ of fracture-brass surfaces layer has reduced the maximum intensity of the electric current that this silk thread can bear.
For this reason, provide a plurality of diameter D
1Be the silk thread of 0.25mm.Silk thread is fixed between two electric terminals, in the deionized water that described electric terminal immersion is 20 ℃.Do not make silk thread be subjected to any mechanical pulling force.Connect current feedback circuit between the described terminal of device.Increase electric current and rupture, and write down the maximum current intensity that silk thread is allowed up to silk thread.
The result lists in following table.
| Silk thread | The maximum current intensity of bearing |
| Copper | 130A |
| CuZn 37 brass | 75A |
| Apply CuZn 37 brass of the pure zinc of 3 μ m | 75A |
| Apply the pure zinc of 3 μ m and diffuse into CuZn 37 brass of the γ phase of non-fracture then | 75A |
| Apply zinc and draw CuZn 37 brass then with the γ phase that obtains fracture 177 ℃ of following diffusions | 65A |
The test silk thread that it should be noted that the last γ phase that has fracture on the brass core is the described silk thread of instruction according to above-mentioned document US 5,945,010.
Test two
Make then according to diameter D of the present invention
1Be the silk thread A of 0.25mm, this silk thread A comprises the core of being made by CuZn20 brass 2, and this core is coated with β phase sublayer 3 and the obvious γ phase surface layer 4 that ruptures that appearance does not rupture.For this reason, adopting electrolysis is the zinc that the CuZn20 brass wire of 1.20mm applies 29 μ m to diameter.Draw this silk so that its diameter becomes 0.827mm.Make this keep two hours so that this silk is annealed from 400 ℃ stove in air atmosphere, wherein the gradient of temperature rising and decline is ± 1 ℃/min.At last, the silk thread to such diffusion carries out wire-drawing operation so that its diameter D
1Be 0.25mm.The gross thickness that records the coating on the silk thread is about 20 μ m.Visible β phase sublayer 3 constitutes this coating on the wire surface by being in some position, and the γ-brass 4 that is ruptured in all the other positions covers.Therefore, apparent, in drawing step, self do not rupture in the wire-drawing operation process in beta-brass sublayer 3.
Test under the condition identical with the aforementioned silk thread of test in one, the maximum current that this silk thread bears is 75A.The ultimate tensile strength of this silk thread is 750N/mm
2This silk thread can be successfully used to the EDM processing under the mechanical pulling force of 17N.
This test has disclosed the windfall effect in the beta-brass sublayer 3, and this sublayer 3 has strengthened silk thread and born the ability of high electric current, and makes the performance of the silk thread that this performance and superficial layer 4 wherein do not rupture consistent.
Test three
Then, by following manufacturing silk thread B: making diameter is the zinc that the CuZn20 brass core of 1.20mm is coated with 29 μ m, carries out wire-drawing operation then so that the diameter D of silk thread
1Be reduced to 0.25mm.Under 380 ℃, carried out annealing operation 1 hour 15 minutes, to obtain the comprising β phase sublayer 3 that about 16 μ m are thick and the silk thread of the γ phase surface layer 4 that about 4 μ m of substantially rupture (because of also not carrying out wire-drawing operation) are thick.
This silk thread bears the maximum current of 75A.This silk thread has 430N/mm
2Ultimate tensile strength, and can be successfully used to EDM processing, but mechanical pulling force reduces to 10N.
Therefore, the silk thread A according to the present invention that makes in test two shows the silk thread B better mechanical strength than this test.
Test four
Under the condition that is fit to silk thread A and silk thread B, that is to say the EDM speed that compares silk thread A and silk thread B with the mechanical pulling force of 10N.
This test uses the AgieCut Evolution II SFF machine of being made by Agie to carry out.
Condition is as follows: basic technology estcca25nnn300g230050 is fit to have 900N/mm
2The zinc-plated brass wire of intensity, nozzle is pressed against on the workpiece.Processed material is the high steel of 60mm.Mechanical pulling force in the silk thread is reduced to 10N.The EDM speed of silk thread A is 2.515mm/min, and the EDM speed of silk thread B is 2.500mm/min.Therefore, the EDM speed of visible silk thread A increases slightly.
Use identical machine, identical materials and technology estccw25nnn300h250050, be fit to have CuZn20 brass core and the β silk thread of layer mutually, under annealed condition, power on the silk thread is 12N, rupture up to silk thread from 1 value that increases parameter P gradually, observe following maximal rate: the maximal rate of silk thread A is 2.79mm/min (P=27), and the maximal rate of silk thread B is 1.85mm/min (P=19).
The processing of silk thread A has formed striking contrast faster than the data of announcing in this fact of silk thread B and the document US 5,945,010.
Test five
Next study the thickness E of the γ phase of fracture
4Influence, to determine to have the silk thread of best EDM speed.
Utilize diameter to obtain according to silk thread of the present invention for the copper core of 0.9mm.This copper core being applied zinc, carry out wire-drawing operation then, is the middle silk thread of 0.422mm to obtain diameter, and the thickness of its China and foreign countries' zinc layer is 16-19 μ m.Should in the middle of silk thread be elevated to all temps with the various times, thereby form the skin that constitutes mutually with γ mutually by the β of different proportion.After DIFFUSION TREATMENT, make silk thread be in annealed condition.Cold drawn silk operation is formed on diameter D under the work-hardened condition
1EDM silk thread for 0.25mm.Make 4 fracture of γ phase surface layer, and β phase sublayer 3 is kept continuously.γ phase surface layer 4 does not cover all surfaces of silk thread, and writes down the thickness E of this layer in the place that has γ phase surface layer 4
4, this thickness is not average thickness values but maximum ga(u)ge value.
The result concentrates in the following table.
| Silk thread | Diffusion conditions | Bed thickness (then is maximum ga(u)ge if there is the γ layer) | Maximum EDM speed under the E2H50 state | Premature failure in |
| 1 | 400 ℃, 2 hours, in ± 0.5 ℃/min air | The dark outward appearance of β 25 μ m γ, 2 μ m | 4.35mm/min | Not |
| 2 | 380 ℃, 3 hours, in ± 0.5 ℃/min air | The dark outward appearance of β 18 μ m γ, 5 μ m | 4.76mm/min | Not |
| 3 | 380 ℃, 3 hours, ± 0.5 ℃/min silk thread in reel with air-isolation | The bright outward appearance of β 18 μ m γ, 5 μ m | 4.61mm/min | Not |
| 4 | 360 ℃, 2 hours, in ± 0.5 ℃/min air | The outward appearance that β 5 μ m γ 20 μ m irregular colours are even | 4.05mm/min | Be |
| 5 | 320 ℃, 2 hours, in ± 0.5 ℃/min air | The outward appearance that β 5 μ m γ 20 μ m irregular colours are even | 3.7mm/min | Be |
As can be seen, has excessive thickness E
4The γ phase surface layer 4 of fracture can cause silk thread premature failure during processing.
Can release the thickness E of the γ phase surface layer 4 of fracture from above-mentioned test
4, more advantageously be about 2% of silk thread diameter preferably less than 8% of silk thread diameter.
In this respect, the thickness E of continuous beta-brass sublayer 3
3Can advantageously be the 5%-12% of silk thread diameter, more advantageously near 6%.
By providing thickness E for the silk thread of 250 μ m to diameter
4If-there be such layer-be γ phase surface layer 4 and thickness E of about 6 μ m (promptly be slightly larger than diameter 2%)
3Be that 15 μ m-are the continuous beta-brass sublayer 3 of about 6%-of silk thread diameter, then can obtain good taking into account.
With the β of the diffusion fully of surface oxidation mutually silk thread compare, electrically contact windfall effect preferably even exist the γ-brass surfaces layer 4 of the fracture of minute quantity, this superficial layer 4 also to have on the surface of diffusion silk thread.On Agie Evolution II machine, this electrically contacts by the low-down spark of power and constitutes, thereby only allows instrument accurately to locate rather than cut.
Also find to compare, have stained less that the conduction of the γ phase surface layer 4 of fracture and the silk thread of β phase sublayer 3 contacts with the silk thread that is diffused into γ complete obiteration degree mutually.Can think,, also can make the electric conductor cleaning even the γ of fracture exists mutually on a small quantity.Be deposited on that lip-deep any oxide of electric conductor and lubricant are residual can be removed by the scraping effect of uneven wire surface.
Test six
Next research is made according to the possibility with silk thread of CuZn37 brass core (63% copper and 37% zinc) of the present invention, and wherein silk thread is with the low cost manufacturing but still have advantage of the present invention.
Thereby, can obtain satisfied silk thread by carry out the γ phase surface layer 4 that long DIFFUSION TREATMENT forms beta-brass sublayer 3 and ruptures with higher temperature.
For this reason, when diameter is 0.827mm, CuZn37 brass blank is applied the zinc of 9 μ m, in stove, handle then, wherein atmosphere is air, thermograde with+0.5 ℃/min is elevated to 320 ℃ from environment temperature, down continue 11 hours at 320 ℃, drop to environment temperature from 320 ℃ with the thermograde of-0.5 ℃/min.Afterwards, by wire-drawing operation with diameter D
1Reduce to 0.25mm, and silk thread is carried out continuously at LSOR annealing, coiling then.
For the effect that relatively obtains according to the present invention, according in document US 5,945, the method for describing in 010 prepares the specimen of silk thread:
-take CuZn37 brass blank (63% bronze medal and 37% zinc);
-formation thickness is the spelter coating of 6 μ m on the diameter of 0.9 μ m;
-in stove, under air atmosphere, heat-treat with 177 ℃, so that zinc is transformed into γ-brass, and do not form an amount of β phase by diffusion;
-wire drawing is carried out continuously lax annealing to 0.25mm, reels then.
By with traditional naked brass EDM silk thread relatively, described according to document US 5,945,010 silk thread is favourable under low working power, but when increase EDM working power, these advantages have disappeared.
Another test is the average thickness that increases the γ-brass surfaces layer 4 of fracture by the thickness that increases spelter coating.Yet the silk thread of acquisition is proved to be fragility, and can not use in the EDM machine, and this machine can make the silk thread bending for a silk process automatically.
Then, under the same operation condition, compare according to document US 5,945, the maximum EDM speed of 010 silk thread and according to the maximum EDM speed of silk thread of the present invention, according to document US 5,945,010 silk thread has core of being made by CuZn37 brass 2 and the γ-brass surfaces layer 4 that ruptures, silk thread according to the present invention has the core of being made by CuZn37 brass 2, and has the γ-brass surfaces layer 4 of beta-brass sublayer 3 and fracture:
| Silk thread | The γ layer of CuZn37+ fracture | The γ layer of CuZn37+ β layer+fracture |
| EDM speed | 119mm 2/min | 120.5mm 2/min |
If there is beta-brass intermediate part-layer 3, then silk thread is not easily broken when bending.Therefore, can increase the integral thickness of the wearing layer of silk thread.
Improved the maximum EDM speed of silk thread, and do not found the silk thread premature failure with core of making by CuZn37 brass.
The present invention is not limited to specifically described embodiment, but comprises various modifications and general example in the scope that falls into claims.
Claims (21)
1. be used for the wire electrode (1) of spark machined, this wire electrode (1) comprising:
-the core (2) made by copper, copper alloy or brass;
-Brass coating,
It is characterized in that this Brass coating comprises stacked:
-beta-brass sublayer (3); And
-superficial layer (4), this superficial layer (4) have γ-chalocopyrite structure of locating to expose the fracture of beta-brass at crackle (5a).
2. wire electrode according to claim 1 is characterized in that, described beta-brass is filled the crackle (5a) in described γ-brass surfaces layer (4) at least partly.
3. wire electrode according to claim 1 and 2 is characterized in that, described beta-brass sublayer (3) is continuous.
4. according to each described wire electrode in the claim 1 to 3, it is characterized in that the thickness (E of the γ of described fracture-brass surfaces layer (4)
4) less than the diameter (D of described wire electrode
1) 8%, preferably less than the diameter (D of described wire electrode
1) 5%.
5. according to each described wire electrode in the claim 1 to 4, it is characterized in that the thickness (E of described beta-brass sublayer (3)
3) at the diameter (D of described wire electrode
1) 5% to 12% scope in.
6. according to claim 4 or 5 described wire electrodes, it is characterized in that the combination thickness (E of the γ of described fracture-brass surfaces layer (4) and described beta-brass sublayer (3)
3+ E
4) less than the diameter (D of described wire electrode
1) 10%.
7. wire electrode according to claim 6 is characterized in that, the thickness (E of the γ of described fracture-brass surfaces layer (4)
4) be the diameter (D of described wire electrode
1) about 2%, the thickness (E of described beta-brass sublayer (3)
3) be the diameter (D of described wire electrode
1) about 6%.
8. according to each described wire electrode in the claim 1 to 7, it is characterized in that, the outer surface of described γ-brass surfaces layer (4) be oxidation and be dark-coloured.
9. according to each described wire electrode in the claim 1 to 7, it is characterized in that the outer surface of the γ of described wire electrode-brass surfaces layer (4) is oxidation, can catoptrical bright appearance but still have.
10. according to each described wire electrode in the claim 1 to 7, it is characterized in that, decompose the average thickness (E that measures resulting oxide layer (6) by selectivity
0) in the scope of the extremely about 250nm of about 100nm.
11. each described wire electrode in 10 is characterized in that oxide layer (6) mainly comprises zinc oxide according to Claim 8.
12., it is characterized in that described core (2) is made less than 40% brass by zinc content according to each described wire electrode in the claim 1 to 11.
13. wire electrode according to claim 12 is characterized in that, described core (2) is made by the brass that contains 20% zinc.
14., it is characterized in that described core (2) is that about 37% CuZn37 alloy is made by zinc content according to each described wire electrode in the claim 1 to 11.
15., it is characterized in that described core (2) is made of copper according to each described wire electrode in the claim 1 to 11.
16. be used for making method, it is characterized in that this method comprises the steps: according to each described wire electrode of claim 1 to 15
A) provide the core of making by copper or brass (2);
B) utilize electrolysis to go up and cover the zinc layer, to form pre-blank at described core (2);
C) if necessary, described pre-blank is carried out first wire-drawing operation;
D), temperature and time is chosen to make because the copper of tectal zinc and core (2) or the diffusion between the brass form the blank with beta-brass sublayer (3) and surperficial oxidized γ-brass surfaces layer (4) with the temperature between about 200 ℃ and about 400 ℃ and continue in stove, the described pre-blank that is pulled through silk to be annealed to about 40 hours time in about 2 hours;
E) blank to such acquisition carries out the second cold drawn silk operation, so that it reaches final diameter (D
1) and make γ-brass surfaces layer (4) rupture.
17. method according to claim 16 is characterized in that, described second wire-drawing operation makes diameter reduce about 40% to about 78%.
18., it is characterized in that described first wire-drawing operation makes diameter reduce about 40% to about 60% according to claim 16 or 17 described methods.
19. according to each described method in the claim 16 to 18, it is characterized in that, described annealing steps d) carry out in stove with such temperature and duration, this temperature and time is chosen to make after step e) the average thickness (E that decomposes the oxide layer (6) that measures by selectivity on wire electrode
0) at about 100nm between about 250nm.
20., it is characterized in that described annealing steps d according to each described method in the claim 16 to 19) in air, carry out, thus make the outer surface of described γ-brass surfaces layer (4) oxidized.
21. according to each described method in the claim 16 to 19, it is characterized in that, carrying out annealing steps d) in, by limiting oxidation in the big envelope that pre-blank is packaged in sealing or semitight.
Applications Claiming Priority (5)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| FR0501547 | 2005-02-11 | ||
| FR0501547A FR2881973B1 (en) | 2005-02-11 | 2005-02-11 | COMPOSITE WIRE FOR ELECTROSION |
| FR0508589A FR2881974B1 (en) | 2005-02-11 | 2005-08-17 | COMPOSITE WIRE FOR ELECTROEROSION. |
| FR0508589 | 2005-08-17 | ||
| PCT/FR2006/000304 WO2006085006A1 (en) | 2005-02-11 | 2006-02-10 | Composite wire for electrical discharge machining |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CN101115580A true CN101115580A (en) | 2008-01-30 |
| CN101115580B CN101115580B (en) | 2012-02-29 |
Family
ID=34954865
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN2006800045646A Active CN101115580B (en) | 2005-02-11 | 2006-02-10 | Composite wire for electrical discharge machining |
Country Status (2)
| Country | Link |
|---|---|
| CN (1) | CN101115580B (en) |
| FR (1) | FR2881973B1 (en) |
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| Publication number | Priority date | Publication date | Assignee | Title |
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| FR2911806B1 (en) * | 2007-01-29 | 2009-03-13 | Thermocompact Sa | ELECTRODE WIRE FOR ELECTROEROSION |
| FR3083466B1 (en) * | 2018-07-03 | 2020-12-18 | Thermocompact Sa | ELECTRODE WIRE WITH POROUS LAYER FOR ELECTROEROSION |
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|---|---|---|---|---|
| US4977303A (en) * | 1984-08-28 | 1990-12-11 | Charmilles Technologie S.A. | Zinc or cadmium coated, surface oxidized electrode wire for EDM cutting of a workpiece; and method for forming such a wire |
| DE19510740A1 (en) * | 1995-03-24 | 1996-10-02 | Berkenhoff Gmbh | Wire electrode and method for producing a wire electrode, in particular for the spark erosion method |
| CN1188703A (en) * | 1996-11-05 | 1998-07-29 | 赵秀卿 | Copper medium osmosis type multiple metal universal welding rod |
| ATE320882T1 (en) * | 1997-07-30 | 2006-04-15 | Ki Chul Seong | METHOD FOR PRODUCING POROUS ELECTRODE WIRE FOR SPARK EDM MACHINES AND STRUCTURE OF THE ELECTRODE WIRE |
| US5945010A (en) * | 1997-09-02 | 1999-08-31 | Composite Concepts Company, Inc. | Electrode wire for use in electric discharge machining and process for preparing same |
| ES2303517T3 (en) * | 2001-09-21 | 2008-08-16 | Berkenhoff Gmbh | THREAD ELECTRODE FOR CUTTING BY ELECTROEROSION. |
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2005
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Also Published As
| Publication number | Publication date |
|---|---|
| FR2881973B1 (en) | 2007-05-11 |
| CN101115580B (en) | 2012-02-29 |
| FR2881973A1 (en) | 2006-08-18 |
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