CN112496480A - Free insulating particle assisted electrolytic wire cutting machining device and method - Google Patents

Free insulating particle assisted electrolytic wire cutting machining device and method Download PDF

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Publication number
CN112496480A
CN112496480A CN202011329290.6A CN202011329290A CN112496480A CN 112496480 A CN112496480 A CN 112496480A CN 202011329290 A CN202011329290 A CN 202011329290A CN 112496480 A CN112496480 A CN 112496480A
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electrolytic
wire electrode
wire
workpiece
free insulating
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CN202011329290.6A
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CN112496480B (en
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房晓龙
韩钊
朱荻
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Nanjing University of Aeronautics and Astronautics
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Nanjing University of Aeronautics and Astronautics
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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
    • 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
    • B23H11/00—Auxiliary apparatus or details, not otherwise provided for
    • 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
    • B23H11/00—Auxiliary apparatus or details, not otherwise provided for
    • B23H11/003—Mounting of workpieces, e.g. working-tables
    • 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
    • B23H7/34—Working media

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  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Electrochemistry (AREA)
  • Electrical Discharge Machining, Electrochemical Machining, And Combined Machining (AREA)

Abstract

The invention relates to a free insulating particle auxiliary electrolytic wire cutting processing device and a method. The device includes: the machining device comprises an electrolyte tank, electrolyte, free insulating particles, a workpiece to be machined, a wire electrode and a power supply; the electrolyte is arranged in the electrolyte tank, and the free insulating particles are arranged in the electrolyte; one end of a workpiece to be machined and one end of a wire electrode are inserted into the electrolyte, the other end of the workpiece to be machined is connected with the positive electrode of a power supply, and the other end of the wire electrode is connected with the negative electrode of the power supply; switching on a power supply, and carrying out electrolytic wire cutting machining along with the movement of the wire electrode; in the electrolytic wire cutting machining process, the free insulating particles fill an electrolytic machining region between the wire electrode and the workpiece to be machined, and the free insulating particles rub against the surface of the wire electrode and the surface of the workpiece to be machined to remove electrolytic products adhering to the surface of the wire electrode. The invention can shield and weaken the secondary corrosion of stray current to a processed area, improve the processing precision and improve the surface quality of a workpiece to be processed.

Description

Free insulating particle assisted electrolytic wire cutting machining device and method
Technical Field
The invention relates to the field of electrolytic machining, in particular to a device and a method for assisting in cutting and machining electrolytic wires by free insulating particles.
Background
The electrolytic wire cutting technology is a special processing method which takes a metal wire or a metal rod as a tool cathode and takes a workpiece as an anode to carry out cutting processing through electrochemical dissolution reaction of electrolyte. The electrolytic wire cutting process has no cathode loss; the method is suitable for processing high-hardness alloy; the processed surface has no recast layer, microcrack and other advantages. The method can be used for processing narrow-slit microgrooves and structures with large depth-width ratio, and can also be used for processing complex ruled surface members by combining multi-axis numerical control motion.
During the cutting and processing of the electrolytic wire, an electric field is mainly distributed in a processing gap between the wire electrode and a workpiece joint, and materials are normally dissolved and removed in an end face processing gap under the action of high current density; stray current is formed in a side face machining gap under the action of low current density and behind the cutting seam, secondary machining is conducted on the surface of the machined cutting seam, stray corrosion is conducted on a non-machined area, and machining precision and surface quality are reduced. For metals and alloys which are easy to passivate such as titanium alloy, nickel-based high-temperature alloy and the like, the defect of electrolytic machining surface pitting caused by low-density stray current is very common, and the problem is urgently needed to be solved in high-surface-quality machining occasions.
In order to weaken or eliminate the influence of stray current, researchers have conducted a great deal of research, and the influence of the stray current is often suppressed by coating an insulating coating on the non-working surface of a tool cathode or applying an auxiliary electrode in conventional electrolytic machining such as electrolytic punching, electrolytic milling and the like; the common ultrashort pulse power supply used in the micro-electrochemical machining reduces the current action range and improves the machining precision.
For the cutting and processing of the electrolytic wire, the arrangement of the auxiliary anode is limited by space due to the small diameter of the wire electrode and the narrow processing cutting seam. Due to the limitation of power, the ultrashort pulse power supply cannot be used for the electrolytic wire cutting processing of the macroscopic structure. Researchers propose an axial flushing method to limit the flowing range of electrolyte mainly in the end face machining gap so as to inhibit the stray corrosion of the machined surface behind the cutting seam; however, because the electrolyte flows in a divergent distribution along the thickness direction of the workpiece, the section of the kerf inlet of the workpiece is always in a conical shape, and the precision is poor. Researchers put forward that insulating paint is coated on the back of the wire electrode and the part of the wire electrode positioned in a non-machining gap or an insulating sleeve is installed to shield an electric field; ventilating on the back of the line electrode along the axial direction of the line electrode to inhibit the distribution of a flow field; the surface wettability of the wire electrode is regulated, and an air film is generated to inhibit the electric field distribution, but in order to ensure that the working surface of the wire electrode is just opposite to the feeding direction, the method needs to add an auxiliary device, and the operation is complex.
Disclosure of Invention
The invention aims to provide a device and a method for assisting in cutting and processing free insulating particles by an electrolytic wire, which aim to solve the problem that the existing method for cutting and processing the electrolytic wire needs to be additionally provided with an auxiliary device to ensure that a working surface of a wire electrode is opposite to a feeding direction so as to inhibit the stray corrosion of a processed surface and the distribution of a flow field, so that the operation is complicated.
In order to achieve the purpose, the invention provides the following scheme:
a free insulating particle-assisted electrolytic wire-cutting machining device comprising: the machining device comprises an electrolyte tank, electrolyte, free insulating particles, a workpiece to be machined, a wire electrode and a power supply;
the electrolyte is arranged in the electrolyte tank, and the free insulating particles are arranged in the electrolyte;
one end of the workpiece to be machined and one end of the wire electrode are inserted into the electrolyte, the other end of the workpiece to be machined is connected with the positive electrode of the power supply, and the other end of the wire electrode is connected with the negative electrode of the power supply;
switching on the power supply, and carrying out electrolytic wire cutting machining along with the movement of the wire electrode; in the process of electrolytic wire cutting machining, the free insulating particles fill an electrolytic machining area between the wire electrode and the workpiece to be machined so as to shield an electric field of the electrolytic machining area in real time; and the free insulating particles rub the surface of the wire electrode and the surface of the workpiece to be machined so as to improve the surface quality of the electrolytic machining area and remove electrolytic products attached to the surface of the wire electrode.
Optionally, the bulk density of the free insulating particles is 0.8 to 1.2 times of the density of the electrolyte.
Optionally, a diameter of a single free insulating particle of the free insulating particles is greater than a half of a difference between a kerf width and a wire electrode diameter, and is smaller than the kerf width.
Optionally, the method further includes: a wire electrode clamp;
the wire electrode clamp is used for clamping the wire electrode.
Optionally, the method further includes: a workpiece holder;
the workpiece clamp is used for clamping the workpiece to be machined.
Optionally, during the electrolytic wire cutting process, the wire electrode performs a rotational motion or a reciprocating motion.
Optionally, the wire electrode is a solid wire, a solid metal rod or a metal tube with holes on the side surface.
A free insulating particle assisted electrolytic wire cutting processing method comprises the following steps:
clamping a workpiece to be processed on the free insulating particle auxiliary electrolytic wire cutting processing device;
adding free insulating particles into the electrolyte tank so that the electrolytic processing area is filled with the free insulating particles;
inserting one end of the workpiece to be machined and one end of a wire electrode into an electrolyte tank provided with electrolyte and the free insulating particles, wherein the other end of the workpiece to be machined is connected with a positive electrode of a power supply, and the other end of the wire electrode is connected with a negative electrode of the power supply;
and switching on the power supply, and carrying out electrolytic wire cutting machining along with the movement of the wire electrode.
Optionally, the bulk density of the free insulating particles is 0.8 to 1.2 times of the density of the electrolyte.
Optionally, a diameter of a single free insulating particle of the free insulating particles is greater than a half of a difference between a kerf width and a wire electrode diameter, and is smaller than the kerf width.
According to the specific embodiment provided by the invention, the invention discloses the following technical effects: the invention provides a free insulating particle auxiliary electrolytic wire cutting processing device and a method, wherein free insulating particles are added into an electrolytic processing area between an electrolytic cell filling wire electrode and a workpiece to be processed, so that the secondary corrosion of stray current to the processed area can be shielded and weakened by the insulating particles flowing during processing, and the processing precision can be improved without adding an auxiliary device; meanwhile, the particles have a trace friction effect on the surface of the seam, and the surface quality is favorably improved.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings needed to be used in the embodiments will be briefly described below, and it is obvious that the drawings in the following description are only some embodiments of the present invention, and it is obvious for those skilled in the art to obtain other drawings without inventive exercise.
FIG. 1 is a schematic diagram of an electrolytic wire cutting process using a free insulation particle-assisted electrolytic wire cutting apparatus according to the present invention;
FIG. 2 is a flow chart of a free insulation particle assisted electrolytic wire cutting process according to the present invention;
FIG. 3 is a current diagram of auxiliary electrolytic wire cutting without free insulating particles obtained by COMSOL Multiphysics simulation;
FIG. 4 is a diagram of a free insulating particle assisted electrowinning wire cut current from COMSOL Multiphysics simulation;
FIG. 5 is a graph of the wire kerf side current density distribution for particle and particle free wire based simulation from COMSOL Multiphysics.
Description of the symbols: 1. x-axis, 2, an electrolyte tank, 3, electrolyte, 4, free insulating particles, 5, a liquid inlet pipe, 6, a Z-axis, 7, a power supply, 8, a wire electrode clamp, 9, a wire electrode, 10, a workpiece clamp, 11, a workpiece to be machined, 12 and a Y-axis.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
The invention aims to provide a free insulating particle-assisted electrolytic wire cutting device and a free insulating particle-assisted electrolytic wire cutting method, which can improve the processing precision and the surface quality.
In order to make the aforementioned objects, features and advantages of the present invention comprehensible, embodiments accompanied with figures are described in further detail below.
Fig. 1 is a schematic diagram of electrolytic wire cutting of the free insulating particle-assisted electrolytic wire cutting device according to the present invention, and as shown in fig. 1, the free insulating particle-assisted electrolytic wire cutting device includes: the device comprises an electrolyte tank 2, an electrolyte 3, free insulating particles 4, a workpiece to be machined 11, a wire electrode 9 and a power supply 7; the electrolyte 3 is arranged in the electrolyte tank 2, and the free insulating particles 4 are arranged in the electrolyte 3; one end of the workpiece to be machined 11 and one end of the wire electrode 9 are inserted into the electrolyte 3, the other end of the workpiece to be machined 11 is connected with the positive electrode of the power supply 7, and the other end of the wire electrode 9 is connected with the negative electrode of the power supply 7; turning on the power supply 7, and performing electrolytic wire cutting machining along with the movement of the wire electrode 9; in the process of electrolytic wire cutting machining, the free insulating particles 4 fill an electrolytic machining area between the wire electrode 9 and the workpiece 11 to be machined so as to shield an electric field of the electrolytic machining area in real time; and the free insulating particles 4 rub the surface of the wire electrode 9 and the surface of the workpiece 11 to be machined so as to improve the surface quality of the electrolytic machining area and remove electrolytic products attached to the surface of the wire electrode 9.
In an optional embodiment of the present invention, the bulk density of the free insulating particles 4 is 0.8 to 1.2 times the density of the electrolyte 3.
In an alternative embodiment of the present invention, the diameter of a single free insulating particle 4 of the free insulating particles 4 is larger than half of the difference between the kerf width and the wire electrode 9 diameter and smaller than the kerf width.
The free insulating particles 4 with the bulk density close to that of the electrolyte 3 are selected to be suspended in the electrolyte 3 and can be densely pressed into the wire electrode 9 and a processing area of a workpiece, so that the stray electric field in the processed area is shielded. The single free insulating particle 4 with the diameter larger than (kerf width-electrode diameter)/2 and smaller than the kerf width is selected, so that the normal electrolytic processing is not influenced on the premise of ensuring the particle insulating effect.
When the density of the selected particles is too high as compared with the electrolyte 3, the particles sink to deteriorate the fluidity, and the movement of the wire electrode 9 is hindered to prevent the wire electrode from being fed normally. When the density of the selected particles is less than the electrolyte 3, the particles float so that they cannot bury the wire electrode 9 and the workpiece. Therefore, the free insulating particles 4 with the bulk density close to the density of the electrolyte 3 are selected, the particle mobility is good, the particles can be automatically filled when the wire electrode 9 moves, the free particles continuously fill the cutting seams at the rear part of the wire electrode 9 along with the movement of the wire electrode 9, the electric field of a processed area is shielded in real time, the surface of the processed cutting seams and the surface of the wire electrode 9 are slightly rubbed, the surface quality of the processed area is improved, and electrolytic products attached to the surface of the wire electrode 9 are removed. In principle, the smaller the particle diameter of the particles, the better the insulation effect, but when the particle diameter is smaller than the end face machining gap, the particles enter the end face machining gap, affecting the normal electrolytic machining. The single free insulating particle 4 with the diameter larger than (kerf width-electrode diameter)/2 and smaller than the kerf width is selected, so that the effects of good insulation and trace friction on the processed surface can be achieved, and the normal electrolytic processing can not be influenced.
As an optional implementation method of the present invention, the present invention further includes: a wire electrode holder 8 and a work holder 10; the wire electrode clamp 8 is used for clamping the wire electrode 9; the workpiece holder 10 is used for holding the workpiece 11 to be processed.
As an alternative method of implementing the present invention, the wire electrode 9 is rotated or reciprocated during the electrolytic wire cutting process.
As an alternative implementation method of the present invention, the wire electrode 9 is a solid wire, a solid metal rod or a metal tube with holes on the side surface.
The wire electrode 9 rotating or reciprocating drives the particles to slightly rub on the machined surface, and the metal wire electrode 9 improves the fluidity of the particles in the cutting seams through radial flushing.
The moving wire electrode 9 or the metal wire electrode 9 spraying liquid radially can make the particles in the cut flow fast, and improve the self-filling capability of the particles, thereby enhancing the insulation shielding capability of the processed cut and the friction capability of the processed cut surface and the wire electrode 9 surface.
As an optional embodiment, the present invention further comprises: an X axis 1, a Y axis 12, a Z axis 6 and a liquid inlet pipe 5;
the workpiece 11 to be machined and the wire electrode 9 are parallel to the Z axis 6, the workpiece 11 to be machined is clamped on the electrolytic wire cutting device, and the relative positions of the X axis 1 and the Y axis 12 are adjusted to be in tool setting with the workpiece 11 to be machined.
Fig. 2 is a flow chart of a method for processing a free insulation particle assisted electrolytic wire cutting according to the present invention, and as shown in fig. 2, the method for processing a free insulation particle assisted electrolytic wire cutting comprises:
step 201: and clamping the workpiece 11 to be processed on the free insulating particle 4 auxiliary electrolytic wire cutting processing device.
Step 202: free insulating particles 4 are added to the electrolytic bath 2 so that the electrolytic processing zone is filled with the free insulating particles 4. The bulk density of the free insulating particles 4 is 0.8-1.2 times of the density of the electrolyte 3, so that the free insulating particles are suspended in the electrolyte 3; the single diameter of the free insulating particles 44 is larger than the selected single diameter (kerf width-electrode diameter)/2 and smaller than the kerf width;
step 203: one end of the workpiece to be machined 11 and one end of the wire electrode 9 are inserted into the electrolyte tank 2 in which the electrolyte 3 and the free insulating particles 4 are placed, the other end of the workpiece to be machined 11 is connected to the positive electrode of the power supply 7, and the other end of the wire electrode 9 is connected to the negative electrode of the power supply 7.
Step 204: the power supply 7 is turned on, and the wire electrode 9 is moved to perform the electrolytic wire cutting process.
FIG. 3 is a free insulation particle-free auxiliary electrolytic wire cutting current chart obtained by COMSOL Multiphysics simulation, and FIG. 4 is a free insulation particle-free auxiliary electrolytic wire cutting current chart obtained by COMSOL Multiphysics simulation. It can be seen visually that the current line of the slit processed side wall is sharply reduced after adding the free insulating particles 4, that is, the stray current is suppressed.
FIG. 5 is a graph of the wire kerf side current density distribution for particle and particle free wire based simulation from COMSOL Multiphysics. Table 1 is a simulation condition schematic table, and the simulation conditions are shown in table 1.
TABLE 1
Figure BDA0002795325660000071
Selecting a single-side wall of a workpiece in the model to draw a current density distribution diagram, and as seen from the graph in FIG. 5, when no particles exist, a current density free area is formed between 0-3 mm (A) of the side wall; a stray low current density area is arranged between 3mm to 8mm (B); the high current density region is processed between 8 to 9mm (C). When particles exist, a region without current density is formed between 0 mm (A ') and 6mm (A') of the side wall; a stray low current density region is arranged between 6mm (B ') and 8mm (B'); the region of high current density is processed between 8-9 mm (C'). It can be seen that the stray low current density area is greatly reduced after adding the free insulating particles 4, and the current density is much lower than the stray current density without particles, and the magnitude of the current density in the high current density area is not affected.
Free insulating particles 4 are added into electrolyte 3 in a processing area to fill an electrolytic wire cutting processing gap, and the insulating ions inhibit the secondary corrosion phenomenon of the processed surface and improve the processing precision of the electrolytic wire cutting; the micro friction of free particles improves the quality of the processed surface and eliminates the adhesion of products on the surface of the wire electrode 9.
The embodiments in the present description are described in a progressive manner, each embodiment focuses on differences from other embodiments, and the same and similar parts among the embodiments are referred to each other.
The principles and embodiments of the present invention have been described herein using specific examples, which are provided only to help understand the method and the core concept of the present invention; meanwhile, for a person skilled in the art, according to the idea of the present invention, the specific embodiments and the application range may be changed. In view of the above, the present disclosure should not be construed as limiting the invention.

Claims (10)

1. A free insulating particle-assisted electrolytic wire-cutting machining device, characterized by comprising: the machining device comprises an electrolyte tank, electrolyte, free insulating particles, a workpiece to be machined, a wire electrode and a power supply;
the electrolyte is arranged in the electrolyte tank, and the free insulating particles are arranged in the electrolyte;
one end of the workpiece to be machined and one end of the wire electrode are inserted into the electrolyte, the other end of the workpiece to be machined is connected with the positive electrode of the power supply, and the other end of the wire electrode is connected with the negative electrode of the power supply;
switching on the power supply, and carrying out electrolytic wire cutting machining along with the movement of the wire electrode; in the process of electrolytic wire cutting machining, the free insulating particles fill an electrolytic machining area between the wire electrode and the workpiece to be machined so as to shield an electric field of the electrolytic machining area in real time; and the free insulating particles rub the surface of the wire electrode and the surface of the workpiece to be machined so as to improve the surface quality of the electrolytic machining area and remove electrolytic products attached to the surface of the wire electrode.
2. The free insulating particle-assisted electrolytic wire cutting device according to claim 1, wherein the bulk density of the free insulating particles is 0.8 to 1.2 times the density of the electrolyte.
3. The free insulation particle-assisted electrolytic wire cutting device according to claim 2, wherein a diameter of a single free insulation particle of the free insulation particles is larger than a half of a difference between a kerf width and a wire electrode diameter and smaller than the kerf width.
4. The free insulating particle-assisted electrolytic wire cutting processing device according to claim 3, characterized by further comprising: a wire electrode clamp;
the wire electrode clamp is used for clamping the wire electrode.
5. The free insulating particle-assisted electrolytic wire cutting processing device according to claim 4, characterized by further comprising: a workpiece holder;
the workpiece clamp is used for clamping the workpiece to be machined.
6. The free insulation particle-assisted electrolytic wire cutting machining device according to any one of claims 1 to 5, wherein the wire electrode performs a rotating motion or a reciprocating motion during the electrolytic wire cutting machining.
7. The free insulating particle-assisted electrolytic wire cutting processing device according to claim 6, wherein the wire electrode is a solid wire, a solid metal rod or a metal tube with holes on the side surface.
8. A method for processing free insulation particle-assisted electrolytic wire cutting, which is applied to the device for processing free insulation particle-assisted electrolytic wire cutting according to any one of claims 1 to 7, the method comprising:
clamping a workpiece to be processed on the free insulating particle-assisted electrolytic wire cutting processing device according to any one of claims 1 to 7;
adding free insulating particles into the electrolyte tank so that the electrolytic processing area is filled with the free insulating particles;
inserting one end of the workpiece to be machined and one end of a wire electrode into an electrolyte tank provided with electrolyte and the free insulating particles, wherein the other end of the workpiece to be machined is connected with a positive electrode of a power supply, and the other end of the wire electrode is connected with a negative electrode of the power supply;
and switching on the power supply, and carrying out electrolytic wire cutting machining along with the movement of the wire electrode.
9. The method of claim 8, wherein the bulk density of the free insulating particles is 0.8 to 1.2 times the density of the electrolyte.
10. The method as claimed in claim 9, wherein the diameter of each of the individual free dielectric particles is larger than half of the difference between the kerf width and the wire electrode diameter and smaller than the kerf width.
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