CN101264537A - EDM shaping method of metal bonded diamond grinding wheel with complex profile - Google Patents
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Abstract
一种复杂型面金属结合剂金刚石砂轮的电火花整形方法，所述整形方法包括以下步骤：(1)根据仿形法制作电火花精密整形工具电极；(2)将整形阶段分为：预整形阶段、过渡整形阶段、快速整形阶段、半精整形阶段、精整形阶段；选择各个对应阶段相应的脉冲电参数和进给速度，脉冲电参数包括整形电流和整形电压，媒介为水或高压水雾，控制放电间隙为0.005～0.02mm。本发明提供一种加工效率高、精度高的复杂型面金属结合剂金刚石砂轮的电火花整形方法。
An electric spark shaping method for a metal bond diamond grinding wheel with complex profiles, the shaping method comprises the following steps: (1) making an electric spark precision shaping tool electrode according to the profiling method; (2) dividing the shaping stage into: pre-shaping stage, transitional shaping stage, rapid shaping stage, semi-finishing shaping stage, fine shaping stage; select the corresponding pulse electric parameters and feed speeds for each corresponding stage, the pulse electric parameters include shaping current and shaping voltage, and the medium is water or high-pressure water mist , Control the discharge gap to 0.005 ~ 0.02mm. The invention provides an electric spark shaping method for a metal-bonded diamond grinding wheel with complex profiles with high processing efficiency and high precision.
Description
技术领域 technical field
本发明涉及金属结合剂金刚石砂轮的整形工艺。The invention relates to a shaping process of a metal bonded diamond grinding wheel.
背景技术 Background technique
目前，作为超精密磨削加工领域中的一个关键性技术难题，复杂型面金属结合剂金刚石砂轮朝着进一步复杂、尺寸要求更高的方向发展，传统的机械加工方法早已不能适应这样的加工，随之出现了电火花精密整形工艺方法，用这个工艺方法能取得高效率高精度的整形效果。At present, as a key technical problem in the field of ultra-precision grinding, the metal-bonded diamond grinding wheel with complex profiles is developing in a direction of further complexity and higher size requirements. Traditional mechanical processing methods have long been unable to adapt to such processing. Then there is the EDM precision shaping process, which can achieve high-efficiency and high-precision shaping effects.
发明内容 Contents of the invention
为了克服已有金属结合剂金刚石砂轮的整形工艺的加工效率低、精度不高的不足，本发明提供一种加工效率高、精度高的复杂型面金属结合剂金刚石砂轮的电火花整形方法。In order to overcome the shortcomings of low processing efficiency and low precision of the existing metal bond diamond grinding wheel shaping process, the present invention provides an electric discharge shaping method for metal bond diamond grinding wheels with high processing efficiency and high precision.
本发明解决其技术问题所采用的技术方案是：The technical solution adopted by the present invention to solve its technical problems is:
一种复杂型面金属结合剂金刚石砂轮的电火花整形方法，所述整形方法包括以下步骤：A kind of electric discharge shaping method of metal bond diamond grinding wheel with complicated profile, described shaping method comprises the following steps:
(1)、根据仿形法制作电火花精密整形工具电极；(1) According to the profiling method, the electrode of the EDM precision shaping tool is produced;
(2)、将整形阶段分为：预整形阶段、过渡整形阶段、快速整形阶段、半精整形阶段、精整形阶段；选择各个对应阶段相应的脉冲电参数和进给速度，脉冲电参数包括整形电流和整形电压，媒介为水或高压水雾，控制放电间隙为0.005～0.02mm。(2), the shaping stage is divided into: pre-shaping stage, transition shaping stage, fast shaping stage, semi-fine shaping stage, fine shaping stage; select the corresponding pulse electric parameters and feed speed of each corresponding stage, the pulse electric parameters include shaping Current and shaping voltage, the medium is water or high-pressure water mist, and the discharge gap is controlled to be 0.005-0.02mm.
作为优选的一种方案：在所述步骤(2)中，所述整形电流范围：0～ImaxA，Imax为最大电流；所述整形电压：Umin和Umax，Umin为小电压，Umax为大电压；整个整形时间为t；整形总共进给量为L；最大每次进给量为V。预整形阶段的整形电压为Umin，整形最大电流为Imax/4，每次进给V/2，预修整用时t/3，该阶段共进给L/3；过渡整形阶段开始时整形电压为Umin，整形最大电流为Imax/3，每次进给量为2V/3，逐渐提高整形电流，在进给量达到L/2时，加大电压到Umax，过渡整形用时t/3，该阶段共进给L/4；快速整形阶段的整形电压为Umax，整形电流为Imax，每次进给量为V，快速整形用时t/5，该阶段共进给L/4；半精整形阶段的初始整形电压为Umin，初始整形电流为2/3Imax，并逐步降低整形电流到Imax/3，每次进给量为V/5，半精整形用时t/10，该阶段共进给L/10；精整形阶段的整形电压为Umin，整形电流逐步减少到Imax/12以下，每次进给量为V/5，精整形用时t/20，该阶段共进给L/40。As a preferred solution: in the step (2), the shaping current range: 0～I max A, I max is the maximum current; the shaping voltage: U min and U max , U min is a small voltage , U max is the maximum voltage; the entire shaping time is t; the total feeding amount of shaping is L; the maximum feeding amount each time is V. The shaping voltage in the pre-shaping stage is U min , the shaping maximum current is I max /4, feed V/2 each time, the pre-shaping takes t/3, and the total feeding in this stage is L/3; the shaping voltage at the beginning of the transition shaping stage is U min , the maximum shaping current is I max /3, and the feeding amount is 2V/3 each time, gradually increase the shaping current, when the feeding amount reaches L/2, increase the voltage to U max , and the transition shaping time is t/ 3. The total feed is L/4 in this stage; the shaping voltage in the rapid shaping stage is U max , the shaping current is I max , the feeding amount is V each time, and the fast shaping takes t/5, and the total feeding in this stage is L/4 ;In the semi-finishing stage, the initial shaping voltage is U min , the initial shaping current is 2/3I max , and the shaping current is gradually reduced to I max /3, the feeding amount is V/5 each time, and the half-finishing time is t/10 , the total feed is L/10 in this stage; the shaping voltage in the fine shaping stage is U min , the shaping current is gradually reduced to below I max /12, the feeding amount is V/5 each time, and the fine shaping takes t/20. Feed L/40 in total.
本发明的技术构思为：本发明实现以下工艺方法，利用仿形法制作电火花精密整形工具电极；按照要整形的砂轮型面制定加工用脉冲参数和工艺阶段：整形电流：0-6A；整形电压：120V、160V；媒介：水、高压水雾；工艺阶段一般分为预整形阶段、过渡整形阶段、快速整形阶段、半精整形阶段、精整形阶段；选择各个对应阶段相应的脉冲参数和进给速度；控制放电间隙：放电间隙控制为0.005～0.02mm；选择合理的整形进给速度和深度；降低了电火花精密整形的工艺难度，在整形出具有复杂型面的砂轮，整形工艺指标达到了较高水平。The technical idea of the present invention is: the present invention realizes the following process method, using profiling method to make the electrode of electric spark precision shaping tool; formulate the pulse parameters and process stages for processing according to the grinding wheel profile to be shaped: shaping current: 0-6A; shaping Voltage: 120V, 160V; Medium: water, high-pressure water mist; process stages are generally divided into pre-shaping stage, transition shaping stage, rapid shaping stage, semi-fine shaping stage, and fine shaping stage; Feeding speed; control the discharge gap: the discharge gap is controlled to 0.005 ~ 0.02mm; choose a reasonable shaping feed speed and depth; reduce the process difficulty of EDM precision shaping, and shape the grinding wheel with a complex surface, the shaping process index reaches a higher level.
本发明的有益效果主要表现在：1、加工效率高、精度高；2、工艺简单。The beneficial effects of the present invention are mainly manifested in: 1. High processing efficiency and high precision; 2. Simple process.
附图说明Description of drawings
图1是设计硬质合金刀具设计图。Figure 1 is a design drawing of a cemented carbide tool.
图2是利用仿形法设计的工具电极设计图。Fig. 2 is a design drawing of the tool electrode designed by the profiling method.
具体实施方式 Detailed ways
下面结合附图对本发明作进一步描述。The present invention will be further described below in conjunction with the accompanying drawings.
参照图1～图2，一种复杂型面金属结合剂金刚石砂轮的电火花整形方法，所述整形方法包括以下步骤：With reference to Fig. 1～Fig. 2, a kind of electric discharge shaping method of metal bond diamond grinding wheel of complex profile, described shaping method comprises the following steps:
(1)、根据仿形法制作电火花精密整形工具电极；(1) According to the profiling method, the electrode of the EDM precision shaping tool is produced;
(2)、将整形阶段分为：预整形阶段、过渡整形阶段、快速整形阶段、半精整形阶段、精整形阶段；选择各个对应阶段相应的脉冲电参数和进给速度，脉冲电参数包括整形电流和整形电压，媒介为水或高压水雾，控制放电间隙为0.005～0.02mm。(2), the shaping stage is divided into: pre-shaping stage, transition shaping stage, fast shaping stage, semi-fine shaping stage, fine shaping stage; select the corresponding pulse electric parameters and feed speed of each corresponding stage, the pulse electric parameters include shaping Current and shaping voltage, the medium is water or high-pressure water mist, and the discharge gap is controlled to be 0.005-0.02mm.
在所述步骤(2)中，所述整形电流范围：0～ImaxA，Imax为最大电流；所述整形电压：Umin和Umax，Umin为小电压，Umax为大电压；整个整形时间为t；整形总共进给量为L；最大每次进给量为V。预整形阶段的整形电压为Umin，整形最大电流为Imax/4，每次进给V/2，预修整用时t/3，该阶段共进给L/3；过渡整形阶段开始时整形电压为Umin，整形最大电流为Imax/3，每次进给量为2V/3，逐渐提高整形电流，在进给量达到L/2时，加大电压到Umax，过渡整形用时t/3，该阶段共进给L/4；快速整形阶段的整形电压为Umax，整形电流为Imax，每次进给量为V，快速整形用时t/5，该阶段共进给L/4；半精整形阶段的初始整形电压为Umin，初始整形电流为2/3Imax，并逐步降低整形电流到Imax/3，每次进给量为V/5，半精整形用时t/10，该阶段共进给L/10；精整形阶段的整形电压为Umin，整形电流逐步减少到Imax/12以下，每次进给量为V/5，精整形用时t/20，该阶段共进给L/40。In the step (2), the range of the shaping current: 0～I max A, I max is the maximum current; the shaping voltage: U min and U max , U min is a small voltage, and U max is a large voltage; The whole shaping time is t; the total feeding amount of shaping is L; the maximum feeding amount each time is V. The shaping voltage in the pre-shaping stage is U min , the shaping maximum current is I max /4, feed V/2 each time, the pre-shaping takes t/3, and the total feeding in this stage is L/3; the shaping voltage at the beginning of the transition shaping stage U min , the maximum shaping current is I max /3, and the feeding amount is 2V/3 each time, gradually increase the shaping current, when the feeding amount reaches L/2, increase the voltage to U max , and the transition shaping time is t/ 3. The total feed is L/4 in this stage; the shaping voltage in the rapid shaping stage is U max , the shaping current is I max , the feeding amount is V each time, and the fast shaping takes t/5, and the total feeding in this stage is L/4 ;In the semi-finishing stage, the initial shaping voltage is U min , the initial shaping current is 2/3I max , and the shaping current is gradually reduced to I max /3, the feeding amount is V/5 each time, and the half-finishing time is t/10 , the total feed is L/10 in this stage; the shaping voltage in the fine shaping stage is U min , the shaping current is gradually reduced to below I max /12, the feeding amount is V/5 each time, and the fine shaping takes t/20. Feed L/40 in total.
本实施例的加工刀具如图1所示，在型号为MM7120A精密卧轴矩台平面磨床上进行电火花精密整形，工艺方法步骤如下：The processing tool of this embodiment is shown in Figure 1, and the model is the MM7120A precision horizontal axis rectangular platform surface grinder to carry out electric spark precision shaping, and the process method steps are as follows:
步骤1：根据仿形法制作电火花精密整形工具电极，如图2所示，所有阶段共用时2750分钟，共进给2.5mm，最快进给速度为每次5um；Step 1: According to the profiling method, make the electrode of the EDM precision shaping tool, as shown in Figure 2, the total time for all stages is 2750 minutes, the total feed is 2.5mm, and the fastest feed speed is 5um each time;
步骤2：预整形阶段Step 2: Pre-shaping stage
预整形阶段主要是去除砂轮的边缘部分，且要保证工具电极损耗达到最小，如果工具电极损耗非常大，就会影响接下来的砂轮整形精度，所以必须减少单个脉冲放电的能量。在这个阶段，由于工件(砂轮)的棱角突出，与电极的相对面积小(仅为两条平行线)，尖端放电现象比较严重，为了减少工具电极的损耗，在预整形阶段的整形电压为120V，整形最大电流控制在1.5A以内，严格控制进给量，可快速进给，但每次只能进给2.5um，预修整用时900(±10min)min，总共进给量0.9mm；The pre-shaping stage is mainly to remove the edge part of the grinding wheel, and to ensure that the tool electrode loss is minimized. If the tool electrode loss is very large, it will affect the subsequent grinding wheel shaping accuracy, so the energy of a single pulse discharge must be reduced. At this stage, due to the protruding edges and corners of the workpiece (grinding wheel), the relative area to the electrode is small (only two parallel lines), and the tip discharge phenomenon is relatively serious. In order to reduce the loss of the tool electrode, the shaping voltage in the pre-shaping stage is 120V , the maximum current for shaping is controlled within 1.5A, the feed rate is strictly controlled, and fast feed is possible, but only 2.5um can be fed each time, and the pre-trimming time is 900 (±10min)min, with a total feed rate of 0.9mm;
步骤3：过渡整形阶段Step 3: Transition Shaping Phase
过渡整形阶段衔接预整形阶段和快速整形阶段，此时砂轮与工具电极间的相对面积已逐渐变大，因此可以在满足整形质量的前提下，尽可能提高整形效率，半精整相对于预整形提高了电参数，开始时整形电压为120V，整形电流为2A，电火花整形效率相比预整形阶段提高，所以每次进给可提高到3.3um，同时逐渐提高整形电流，当砂轮表面被逐渐的蚀除，在加工深度进行到1.2个毫米左右时，砂轮与电极的相对面积已经是两个面，相对面积比较大。这个时候火花放电稳定，电火花呈斜线状，效果比较好，这个时候可以考虑加大电压到160V进行加工，相应的进给量也可以适当的增大到3.3um，此时进入快速整形阶段，过渡整形阶段用时900(±10min)min，总共进给0.64mm；The transitional shaping stage connects the pre-shaping stage and the rapid shaping stage. At this time, the relative area between the grinding wheel and the tool electrode has gradually increased. Therefore, the shaping efficiency can be improved as much as possible under the premise of satisfying the shaping quality. The electrical parameters are improved. At the beginning, the shaping voltage is 120V, and the shaping current is 2A. Compared with the pre-shaping stage, the EDM shaping efficiency is improved, so each feed can be increased to 3.3um. At the same time, the shaping current is gradually increased. When the surface of the grinding wheel is gradually When the machining depth reaches about 1.2 millimeters, the relative area of the grinding wheel and the electrode is already two sides, and the relative area is relatively large. At this time, the spark discharge is stable, the electric spark is oblique, and the effect is better. At this time, it can be considered to increase the voltage to 160V for processing, and the corresponding feed rate can also be appropriately increased to 3.3um. At this time, it enters the rapid shaping stage. , the transition shaping stage takes 900(±10min)min, and the total feed is 0.64mm;
步骤4：快速整形阶段Step 4: Rapid Shaping Phase
快速整形阶段，也即粗整形阶段，由于此时砂轮的表面已基本成形，所以主要是为了减少圆度误差以及快速的去除铸铁粘合剂，根据本实验快速整形规准，设定整形电压为160V，整形电流为6A，每次进给为0.5um。当加工溅出的火花成两条相交的火花线的时候，说明砂轮已经成形，此时进入半精整形阶段，快速整形阶段时间为540(±10min)min，总共进给0.58mm；In the rapid shaping stage, that is, the rough shaping stage, since the surface of the grinding wheel has been basically formed at this time, it is mainly to reduce the roundness error and quickly remove the cast iron adhesive. According to the rapid shaping standard of this experiment, the shaping voltage is set to 160V, the shaping current is 6A, and each feed is 0.5um. When the sparks from the processing form two intersecting spark lines, it means that the grinding wheel has been formed. At this time, it enters the semi-finishing shaping stage. The rapid shaping stage takes 540 (±10min) min, and the total feed is 0.58mm;
步骤5：半精整形阶段Step 5: Semi-finishing stage
半精整形主要是由于在快速整形阶段时，砂轮全部廓型已经整形出来，主要为了保证砂轮的表面粗糙度，所以改变电规准。半精整形是快速整形阶段和精整形阶段中的过渡阶段，设定整形电压为160V，整形电流降为4A，同时逐渐减低整形电流，直到整形电压为120V，整形电流降为2A，每次进给严格控制在0.1um，半精整形阶段用时270(±10min)min，总共进给0.28mm；The semi-finishing is mainly due to the fact that the entire profile of the grinding wheel has been shaped during the rapid shaping stage, and the electric gauge is changed mainly to ensure the surface roughness of the grinding wheel. Semi-fine shaping is a transitional stage between the fast shaping stage and the fine shaping stage. Set the shaping voltage to 160V, and reduce the shaping current to 4A. At the same time, gradually reduce the shaping current until the shaping voltage is 120V, and the shaping current drops to 2A. It is strictly controlled at 0.1um, and the semi-finishing stage takes 270 (±10min)min, with a total feed of 0.28mm;
步骤6：精整形阶段Step 6: Fine shaping stage
为了继续提高砂轮的精密整形精度，电火花整形进入最后一个阶段，即精整形阶段，为了提高砂轮整形精度，减少放电痕直径，也就是减少单个脉冲放电的能量，通过减少整形电流实现，同时略微进给，每次进给控制在0.1um，设定整形电压为120V，让整形电流逐渐降低到0.5A以下，精整形阶段用时140(±5min)min，总共进给0.02mm。In order to continue to improve the precision shaping accuracy of the grinding wheel, EDM shaping enters the last stage, namely the fine shaping stage. In order to improve the shaping accuracy of the grinding wheel, reduce the diameter of the discharge trace, that is, reduce the energy of a single pulse discharge, by reducing the shaping current, and at the same time slightly Feed, the feed is controlled at 0.1um each time, the shaping voltage is set to 120V, and the shaping current is gradually reduced to below 0.5A. The fine shaping stage takes 140 (±5min) min, and the total feeding is 0.02mm.
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| CNA2008100614084A Pending CN101264537A (en) | 2008-05-09 | 2008-05-09 | EDM shaping method of metal bonded diamond grinding wheel with complex profile |
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Cited By (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN103433583A (en) * | 2013-09-06 | 2013-12-11 | 福耀玻璃（重庆）配件有限公司 | Tool electrode assembly and grinding wheel repair machine |
| CN111230761A (en) * | 2020-03-03 | 2020-06-05 | 沈阳工业大学 | A kind of grinding wheel manufacturing method and manufacturing device for silicon wafer chamfering |
| CN111515482A (en) * | 2020-04-27 | 2020-08-11 | 北京工业大学 | Metal-based grinding wheel precision forming and shaping method |
| CN112454171A (en) * | 2020-12-04 | 2021-03-09 | 郑州磨料磨具磨削研究所有限公司 | Method and device for dressing superhard material grinding wheel |
-
2008
- 2008-05-09 CN CNA2008100614084A patent/CN101264537A/en active Pending
Cited By (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN103433583A (en) * | 2013-09-06 | 2013-12-11 | 福耀玻璃（重庆）配件有限公司 | Tool electrode assembly and grinding wheel repair machine |
| CN103433583B (en) * | 2013-09-06 | 2015-10-28 | 福耀玻璃（重庆）配件有限公司 | Tool-electrode assembly and emery wheel repair machine |
| CN111230761A (en) * | 2020-03-03 | 2020-06-05 | 沈阳工业大学 | A kind of grinding wheel manufacturing method and manufacturing device for silicon wafer chamfering |
| CN111515482A (en) * | 2020-04-27 | 2020-08-11 | 北京工业大学 | Metal-based grinding wheel precision forming and shaping method |
| CN112454171A (en) * | 2020-12-04 | 2021-03-09 | 郑州磨料磨具磨削研究所有限公司 | Method and device for dressing superhard material grinding wheel |
| CN112454171B (en) * | 2020-12-04 | 2022-03-01 | 郑州磨料磨具磨削研究所有限公司 | Method and device for dressing superhard material grinding wheel |
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