CN111205591A - 一种可电火花线切割的大型聚醚醚酮模压毛坯件 - Google Patents

一种可电火花线切割的大型聚醚醚酮模压毛坯件 Download PDF

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CN111205591A
CN111205591A CN202010131953.7A CN202010131953A CN111205591A CN 111205591 A CN111205591 A CN 111205591A CN 202010131953 A CN202010131953 A CN 202010131953A CN 111205591 A CN111205591 A CN 111205591A
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曲燕
吴立豪
孙友军
乔占凤
赵玉利
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Dalian Jiangyu New Material Technology Co ltd
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Abstract

一种可电火花线切割的大型聚醚醚酮模压毛坯件，属于模压毛坯件领域。本发明模压毛坯件为基体材料外表面涂覆电镀层制作而成。其中基体材料的材质为聚醚醚酮模压改性料，聚醚醚酮模压改性料由以下重量份原料组成：50‑60份聚醚醚酮树脂、20‑40份碳纤维、10～20份导电填料、0.5～3份分散剂。电镀层为导电类涂料、金属镀层中的一种。本发明与传统大型聚醚醚酮模压毛坯件相比，可采用电火花线切割的方法进行切割加工。同样大小的毛坯件，采用电火花线切割方法加工的效率比传统铣削方法加工的效率提高了一倍。

Description

一种可电火花线切割的大型聚醚醚酮模压毛坯件
技术领域
本发明属于模压毛坯件领域，具体涉及一种可电火花线切割的大型聚醚醚酮模压毛坯件。
背景技术
密封件是当代机械设备中不可缺少的一种零部件，尤其在大型压缩机、大型泵阀制件中都存在着它的身影。现有的密封件常见的为金属制件，金属制件进行切割采用的是传统的电火花线切割的方法，切面端口平整垂直，加工刀口0.04mm～0.1mm，不需要进行二次铣削，无较大的原料浪费，无铣削热变形，加工精度高。
随着时代的进步，这种大型密封件的使用材质也从金属材料过渡到了高分材料，常见的有采用大型聚醚醚酮模压毛坯件加工而成的密封产品。但是这种大型聚醚醚酮模压毛坯件不像传统金属材料那样具有较高的导电性，无法采用电火花线切割的方法进行切割加工，只能使用传统的合金锯片进行铣削。这就造成了铣削后切割表面存在铣削刀痕，铣削处由于摩擦热也造成了外圆尺寸变形，使得模压件尺寸精度变低；另外由于铣削时存在1～2mm锯片刀口预留及2～3mm铣平切口断面预留量，无形中加大了模压毛坯件尺寸，从而增加了模具的制造成本，而铣去的碎削无法重复利用，也造成了树脂原料的浪费。
发明内容
针对上述不足本发明提供一种可电火花线切割的大型聚醚醚酮模压毛坯件，该模压毛坯件可实现高精度切割且原料浪费大幅减少经济性良好。
本发明解决技术问题的模压毛坯件为基体材料外表面涂覆电镀层制作而成。其中基体材料的材质为聚醚醚酮模压改性料，聚醚醚酮模压改性料由以下重量份原料组成：50-60份聚醚醚酮树脂、20-40份碳纤维、10～20份导电填料、0.5～3份分散剂。电镀层为导电类涂料、金属镀层中的一种。
进一步的，导电填料为碳类材料、金属类导电填料中的一种。
进一步的，基体材料表面电阻率为10～106Ω·cm。
进一步的，导电类涂料由漆基和导电添加剂组成，漆基为采用环氧类漆基、丙烯酸类漆基、聚氨酯类极性漆基中的一种，以增加其与聚醚醚酮树脂和导电添加剂的相容性；导电添加剂为金属类、导电类聚合物中的一种，具有较高的导电性。
进一步的，金属镀层所用的材料为金属类、金属氧化物中的一种。
进一步的，金属镀层可以采用真空镀、离子镀、金属熔融喷射等方法实现。
进一步的，电镀层的电阻率为0-102Ω·cm，电镀层的厚度在0.05-0.5mm范围。
原理：电火花线切割的加工原理是对电极和工件施加脉冲电压，使工作液电离出正电荷和负电子，电子轰击工件表面使工件表面正电荷抛出，并瞬时放出大量的热，从而达到对工件表面产生电腐蚀的现象；而传统的大型聚醚醚酮模压毛坯件采用的是高分子材料，不具备导电性，材料内部没有自由的正负电荷，无法进行放电腐蚀，不能采用电火花线切割的方法加工，因此要想使用电火花线切割的方法加工大型聚醚醚酮模压毛坯件就需要提高其本身的导电性使其产生放电腐蚀现象。
有益效果：
(1)与传统大型聚醚醚酮模压毛坯件相比，可采用电火花线切割的方法进行切割加工。同样大小的毛坯件，采用电火花线切割方法加工的效率比传统铣削方法加工的效率提高了一倍。
(2)与传统大型聚醚醚酮模压毛坯件相比，采用电火花线切割加工的毛坯件加工刀口仅有0.04～0.1mm，表面无毛刺，刀口平整度和垂直度都较好，不需要留出锯片刀口加工量和铣平刀口加工量。制作同一规格的毛坯件，由于不需要预留加工量，模具尺寸可以放小，减少了模具加工成本；此外制作的毛坯件也不需要那么大的尺寸，投料量也可以减少，提高了原料的利用率；最后，由于不需要进行二次铣平工序，没有铣平碎削的产生，减少了粉尘污染。
(3)与传统大型聚醚醚酮模压毛坯件相比，采用电火花线切割切削的毛坯件不存在铣削热变形的现象。由于电火花线切割是利用电子轰击工件产生的摩擦热来熔融工件，而电子的轰击速度相当快，属于瞬时熔融，在切割刀口上产生的热量还没有来得及传导给模压件其他部位的时候已经完成了切割，因此除了刀口位置有一定的热度外，模压件其他部位温度几乎保持一致，不会像传统铣削加工那样产生热量传导，造成模压件发生变形的现象。
具体实施方式
下面结合实施例对本发明作进一步说明，其中分散剂购自EKFA公司，如无特殊说明其他原料均可由商业途径购得。
实施例1
本实施例中的基体材料使用的聚醚醚酮模压改性料由以下重量份原料组成：50份聚醚醚酮树脂、20份碳纤维、10份石墨、0.5份分散剂。电镀层为环氧类漆基和Ag粉。整个基体材料的表面电阻率10Ω·cm，电镀层电阻率10Ω·cm，电镀层厚度为0.05mm。
实施例2
本实施例中的基体材料使用的聚醚醚酮模压改性料由以下重量份原料组成：60份聚醚醚酮树脂、40份碳纤维、20份碳纳米管、3份分散剂。电镀层为丙烯酸类漆基和Cu粉。整个基体材料的表面电阻率106Ω·cm，电镀层电阻率80Ω·cm电镀层厚度为0.5mm。
实施例3
本实施例中的基体材料使用的聚醚醚酮模压改性料由以下重量份原料组成：55份聚醚醚酮树脂、30份碳纤维、15份碳纳米管、1份分散剂。电镀层为Cu镀层，Cu镀层通过真空镀方法实现。整个基体材料的表面电阻率104Ω·cm，电镀层电阻率100Ω·cm电镀层厚度为0.3mm。
实施例4
本实施例中的基体材料使用的聚醚醚酮模压改性料由以下重量份原料组成：53份聚醚醚酮树脂、25份碳纤维、15份Cu粉、1份分散剂。电镀层为Al镀层，Al镀层通过离子镀方法实现。整个基体材料的表面电阻率100Ω·cm，电镀层厚度为0.1mm。
实施例5
本实施例中的基体材料使用的聚醚醚酮模压改性料由以下重量份原料组成：59份聚醚醚酮树脂、20份碳纤维、18份Al粉、0.5份分散剂。电镀层为Cr镀层，Cr镀层通过金属熔融喷射方法实现。整个基体材料的表面电阻率103Ω·cm，电镀层电阻率30Ω·cm电镀层厚度为0.08mm。
实施例6
本实施例中的基体材料使用的聚醚醚酮模压改性料由以下重量份原料组成：59份聚醚醚酮树脂、20份碳纤维、18份Al粉、0.5份分散剂。电镀层为聚氨酯类极性漆基和Ag粉。整个基体材料的表面电阻率100Ω·cm，电镀层电阻率0Ω·cm，电镀层厚度为0.08mm。
实施例7
本实施例中的基体材料使用的聚醚醚酮模压改性料由以下重量份原料组成：52份聚醚醚酮树脂、40份碳纤维、20份石墨、0.5份分散剂。电镀层为环氧类漆基和Ag粉。整个基体材料的表面电阻率20Ω·cm，电镀层电阻率60Ω·cm，电镀层厚度为0.08mm。
上述实施例只是用于对本发明的举例和说明，而非意在将本发明限制于所描述的实施例范围内。此外本领域技术人员可以理解的是，本发明不局限于上述实施例，根据本发明的教导还可以做出更多种的变型和修改，这些变型和修改均落在本发明所要求保护的范围内。

Claims (10)

1.一种可电火花线切割的大型聚醚醚酮模压毛坯件，其特征在于，该模压毛坯件为基体材料外表面涂覆电镀层制作而成；其中基体材料的材质为聚醚醚酮模压改性料，聚醚醚酮模压改性料由以下重量份原料组成：50-60份聚醚醚酮树脂、20-40份碳纤维、10～20份导电填料、0.5～3份分散剂。
2.根据权利要求1所述的一种可电火花线切割的大型聚醚醚酮模压毛坯件，其特征在于，导电填料为碳类材料、金属类导电填料中的一种。
3.根据权利要求1所述的一种可电火花线切割的大型聚醚醚酮模压毛坯件，其特征在于，基体材料表面电阻率为10～106Ω·cm。
4.根据权利要求1所述的一种可电火花线切割的大型聚醚醚酮模压毛坯件，其特征在于，电镀层为导电类涂料、金属镀层中的一种。
5.根据权利要求4所述的一种可电火花线切割的大型聚醚醚酮模压毛坯件，其特征在于，导电类涂料由漆基和导电添加剂组成，漆基为采用环氧类漆基、丙烯酸类漆基、聚氨酯类极性漆基中的一种，导电添加剂为金属类、导电类聚合物中的一种。
6.根据权利要求5所述的一种可电火花线切割的大型聚醚醚酮模压毛坯件，其特征在于，金属类导电添加剂为Ag粉、Cu粉中的一种。
7.根据权利要求4所述的一种可电火花线切割的大型聚醚醚酮模压毛坯件，其特征在于，金属镀层所用的材料为金属类、金属氧化物中的一种。
8.根据权利要求7所述的一种可电火花线切割的大型聚醚醚酮模压毛坯件，其特征在于，金属类金属镀层为Cu镀层、Al镀层、Cr镀层中的一种。
9.根据权利要求4或6所述的一种可电火花线切割的大型聚醚醚酮模压毛坯件，其特征在于，金属镀层采用真空镀、离子镀、金属熔融喷射中的一种方法实现。
10.根据权利要求1所述的一种可电火花线切割的大型聚醚醚酮模压毛坯件，其特征在于，电镀层的电阻率为0-102Ω·cm，电镀层的厚度在0.05-0.5mm范围。
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