CN115870708B - Electrode machining method with thread-like characteristics - Google Patents
Electrode machining method with thread-like characteristics Download PDFInfo
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- CN115870708B CN115870708B CN202310064502.XA CN202310064502A CN115870708B CN 115870708 B CN115870708 B CN 115870708B CN 202310064502 A CN202310064502 A CN 202310064502A CN 115870708 B CN115870708 B CN 115870708B
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Abstract
The invention belongs to the technical field of electrode processing, and discloses an electrode processing method with thread-like characteristics, which comprises the following steps: electrode design: acquiring an electrode shape matched with a discharge part of at least one target part with the aid of three-dimensional software from the discharge part with thread-like characteristics, decomposing the electrode shape into a plurality of electrode teeth suitable for CNC machining center machining along the axial direction of the electrode shape, wherein the electrode teeth are provided with tooth parts, the tooth parts of each electrode tooth can jointly form the electrode shape, then uniformly arranging each electrode tooth belonging to the same electrode shape on an electrode table along the axial direction in sequence, and taking a structure formed by the electrode table and each electrode tooth as an electrode machining model; clamping an electrode; programming a processing procedure; and (5) electrode processing. The invention solves a series of problems of the similar threaded electrode, such as multiple burrs, easy damage to the shape and poor surface roughness of the electrode, and provides a solid foundation for EDM processing of the similar parts.
Description
Technical Field
The invention belongs to the technical field of electrode machining, and particularly relates to an electrode machining method with thread-like characteristics.
Background
Currently, EDM is used to machine parts with thread-like features, which are shown in FIG. 1, requiring matched electrodes for electrical discharge machining, but with many sharp or favorable corners, requiring CNC machining centers. When the CNC machining center processes the sharp angle or sharp angle, the problems are that burrs left at the sharp angle and the sharp angle after the machining are large and difficult to remove, the shape is too thin and easy to damage, the machining of the EDM part is seriously affected, and the surface finish of the electrode is required to be good and the sizes of the sharp angle and the sharp angle are required to be accurate. At present, in the processing and manufacturing links, a good method for processing the sharp angle and the burrs of the sharp angle part of the electrode by using a triaxial vertical processing center does not exist, so that the EDM of the part with the similar thread shape is difficult to process to meet the requirement of part design, and the similar thread shape with smaller diameter is difficult to process.
Disclosure of Invention
In view of the above, the present invention aims to provide an electrode processing method with a thread-like feature, so as to solve the problem that sharp corners or sharp corners of an electrode for processing a part with a thread-like shape have burrs and are extremely thin and easily damaged.
In order to achieve the above purpose, the present invention adopts the following technical scheme:
an electrode machining method with thread-like features, comprising the steps of:
electrode design: acquiring an electrode shape matched with a discharge part of at least one target part with the aid of three-dimensional software from the discharge part with thread-like characteristics, decomposing the electrode shape into a plurality of electrode teeth suitable for CNC machining center machining along the axial direction of the electrode shape, wherein the electrode teeth are provided with tooth parts, the tooth parts of each electrode tooth can jointly form the electrode shape, then uniformly arranging each electrode tooth belonging to the same electrode shape on an electrode table along the axial direction in sequence, and taking a structure formed by the electrode table and each electrode tooth as an electrode machining model;
electrode clamping: clamping the electrode blank in a CNC machining center through a clamp;
programming the processing procedure: utilizing programming software to formulate an electrode rough cutting and electrode finish machining working procedure matched with the electrode machining model;
electrode processing: sequentially executing machining procedures of electrode roughing and electrode finishing by a CNC machining center, and obtaining a finished electrode with thread-like characteristics through machining;
wherein in the step electrode design, the obtained electrode structure is suitable for CNC machining, comprising the following steps:
each electrode tooth is provided with a vertical surface participating in discharge, sharp angles or sharp angles are distinguished according to the shape of the electrode, a reinforcing circular arc is added on one side with the sharp angles or the sharp angles according to the actual condition of a target part, a clearance abdication plane is formed on the electrode tooth, and then an R angle is chamfered and tangential with the tooth part.
In a possible implementation manner, the electrode rough cutting machining procedure includes the following steps:
adopting a cavity milling strategy, selecting a D6-D8 cutter, and carrying out rough cutting on the electrode blank to remove the allowance;
adopting a secondary rough cutting machining strategy, and selecting cutters D1-D3 to perform partial rough cutting;
adopting a contour machining strategy, and selecting a cutter of D0.3-D0.6 to perform local rough cutting;
and adopting a contour machining strategy, and selecting a ball cutter matched with the R angle in the tooth part of the electrode tooth to perform partial rough cutting.
In a possible implementation manner, in the electrode roughening processing procedure, the roughening allowance is controlled to be not less than 0.05MM and not more than 0.07 MM.
In a possible implementation manner, the electrode finishing machining procedure comprises the following steps:
adopting a plane milling strategy, selecting a D2-D4 flat cutter, and finishing the vertical planes of the peripheral abdication of each electrode tooth;
and finishing the thread shape of the electrode teeth and other related surfaces, wherein the related surfaces are required to be processed and molded at one time.
In a possible implementation manner, the finishing electrode tooth thread shape and other related surfaces need to be processed and formed once, and the finishing electrode tooth thread shape and other related surfaces comprise the following steps:
selecting a ball cutter smaller than an R angle in an electrode tooth part, adopting a processing strategy of area milling, setting a reciprocating feed non-steep cutting mode, and enabling the cutting direction to be down milling;
analyzing the shape of the electrode teeth to determine a cutting angle, wherein if the shape of the electrode teeth is an inclined plane and an arc surface, the cutting angle is designated to be parallel to the inclination direction of the threads, and the cutting direction is milled from one end of the electrode teeth to the other end of the electrode teeth; if the electrode tooth has a shape with an inclined surface, an arc surface and a vertical surface, the cutting angle is specified in a direction parallel to the vertical surface, the cutting direction starts milling from the opposite side of the vertical surface of the electrode tooth, mills from one end of the electrode tooth to the top of the vertical surface, then from the top of the vertical surface to the root of the vertical surface, and finally ends at the other end of the electrode tooth.
In a possible implementation manner, in the machining process of electrode finishing, when R in an electrode tooth part is 0.1mm, a cutter with the diameter of D0.2 is selected, the cutter setting amount is 0.01mm, the rotating speed of a machine tool is 30000R/min, the feeding amount is 300mm, and the service life of the cutter is 20min;
when R in the electrode tooth part is 0.15mm, a cutter with the diameter of D0.3 is selected, the cutter setting amount is 0.015mm, the rotating speed of a machine tool is 29000R/min, the feeding amount is 350mm, and the service life of the cutter is 25min;
when R in the electrode tooth part is 0.2mm, a cutter with the diameter of D0.4 is selected, the cutter setting amount is 0.02mm, the rotating speed of a machine tool is 28000R/min, the feeding amount is 400mm, and the service life of the cutter is 35min;
when R in the electrode tooth part is 0.25mm, a cutter with the diameter of D0.5 is selected, the cutter setting amount is 0.025mm, the rotating speed of a machine tool is 27000R/min, the feeding amount is 500mm, and the service life of the cutter is 45min;
when R in the electrode tooth part is 0.3mm, a cutter with the diameter of D0.6 is selected, the cutter setting amount is 0.03mm, the rotating speed of a machine tool is 26000R/min, the feeding amount is 550mm, and the service life of the cutter is 60min.
In a possible implementation, after the machining process of the electrode finishing, a machining process of the electrode finishing is performed again, in which the service life of the ball cutter is doubled.
In a possible implementation manner, the target part is provided with two discharging parts, the two discharging parts are respectively positioned at two ends of the target part, the discharging parts are arc-shaped groove structures with thread-like characteristics, the electrode teeth are sheet-shaped and are provided with tooth parts and end planes matched with the discharging parts, and the end planes of the electrode teeth are arranged on the electrode table in a superposition manner with the electrode table.
In a possible implementation, two adjacent electrode teeth are arranged on the electrode table at a distance suitable for electrical discharge machining.
In a possible implementation manner, the discharge parts at two ends of the target part can be respectively decomposed into three electrode teeth, the electrode teeth of the two discharge parts have the same structure and comprise a first electrode tooth, a second electrode tooth and a third electrode tooth, the first electrode tooth is provided with a tooth sharp angle, a third electrode tooth inclined plane, an inner tooth R angle and a reinforcing arc I and a vertical surface of a first tooth participating in discharge, the second electrode tooth is provided with a tooth utilizing angle, a first tooth inclined plane, an inner tooth R angle and a vertical surface of a second tooth participating in discharge and a reinforcing arc II, and the third electrode tooth is provided with a tooth cambered surface and a tooth inclined plane II; and each electrode tooth is provided with a clearance plane and a abdication.
Compared with the prior art, the invention has the following beneficial effects:
according to the electrode machining method with the thread-like characteristics, the electrode shape obtained from the discharge part of the target part with the thread-like characteristics is decomposed from the electrode design, electrode teeth which are convenient to machine through a CNC machining center can be obtained after decomposition, the electrode teeth which are obtained through decomposition can be convenient to machine sharp corners or sharp corners, auxiliary bodies such as vertical surfaces and reinforcing circular arcs are adopted, and machining procedures of electrode rough cutting and electrode finish machining are sequentially carried out in an arrangement mode which is convenient to feed in the same fixed direction, burrs and thinner shapes of the sharp corners or the sharp corners of the electrode can be controlled within acceptable ranges, and a burr-free state can be achieved.
Drawings
FIG. 1 is a schematic view of a target part with thread-like shape according to an embodiment of the present application;
FIG. 2 is an exploded schematic view of electrode teeth of an exploded discharge portion taken from a target part according to an embodiment of the present application;
FIG. 3 is a schematic view of two sets of electrode teeth with two discharge portions broken away from a target part according to an embodiment of the present application;
FIG. 4 is a schematic view of the structure of two sets of electrode teeth after adding a reinforcing arc according to the embodiment of the present application;
FIG. 5 is a schematic diagram of two sets of electrode teeth in the embodiment of the present application, in which the clearance plane is designed and the electrode teeth of the relief R are inverted
FIG. 6 is a schematic view of an electrode processing model formed after being arranged on an electrode table according to the number of target parts in an embodiment of the present application;
fig. 7 is a schematic diagram of a rough cutting and allowance removing tool path (D8 tool rough cutting) of an electrode machining model according to an embodiment of the present application;
FIG. 8 is a schematic diagram of a partial rough cutting and allowance removing tool path (D3, D1, D0.5 tool partial rough cutting) of an electrode processing model according to an embodiment of the present application;
fig. 9 is a schematic diagram of a partial open rough tool path of a ball cutter (a partial open rough cutter of R0.2) with a similar R angle in an electrode tooth portion of an electrode machining model according to an embodiment of the present application;
FIG. 10 is a schematic view of a finishing tool path of a vertical plane with a tooth-shaped relief in the electrode machining model according to an embodiment of the present application;
FIG. 11 is a schematic view of a finishing electrode tooth thread shape and other relevant surface paths of an electrode machining model according to an embodiment of the present application;
FIG. 12 is a schematic view of the finish machining and cutting direction of the electrode teeth of the all-bevel and cambered surfaces electrode machining model according to the embodiment of the application;
fig. 13 is a schematic finish view and a schematic cutting direction of an electrode tooth with a vertical surface of an electrode machining model according to an embodiment of the present application.
In the figure: 1-a target part; 2-thread-like shape; 3-electrode teeth I; 4-electrode teeth II; 5-electrode teeth III; 6-electrode teeth IV; 7-electrode teeth five; 8-electrode teeth six; 9-sharp corners of tooth parts; 10-tooth angle correction; 11-tooth bevel one; 12-tooth cambered surface; 13-tooth part inclined plane II; 14-R angle in tooth; 15-a vertical face of the second tooth portion participating in the discharge; 16-tooth inclined plane III; 17-a vertical face of the first tooth portion involved in the discharge; 18-reinforcing arc I; 19-reinforcing a second arc; 20-an empty plane; 21-yielding R; 22-large electrode; 23-electrode Z direction reference; 24-electrode blank.
Detailed Description
For the purpose of making the objects, technical solutions and advantages of the embodiments of the present invention more apparent, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present invention, and it is apparent that the described embodiments are some embodiments of the present invention, but not all embodiments of the present invention. The components of the embodiments of the present invention generally described and illustrated in the figures herein may be arranged and designed in a wide variety of different configurations.
The invention is further described with reference to the drawings and specific examples.
Referring to fig. 1-13, an embodiment of the present application provides an electrode processing method with a thread-like shape 2, comprising the following steps:
step S100: electrode design: the electrode shape matched with the discharge part is obtained from the discharge part with the characteristic of the thread-like shape 2 of at least one target part 1 by means of three-dimensional software, the electrode shape is decomposed into a plurality of electrode teeth suitable for CNC machining center machining along the axial direction of the electrode shape, the electrode teeth are provided with tooth parts, the tooth parts of each electrode tooth can jointly form the electrode shape, then each electrode tooth belonging to the same electrode shape is sequentially and uniformly arranged on an electrode table along the axial direction, and the structure formed by the electrode table and each electrode tooth is used as an electrode machining model.
In this step, the electrode design is modeled by three-dimensional software such as UG, and the discharge portion of the target part 1 is characterized by a thread-like shape 2, which is similar to the thread shape, specifically, may be a shape with incomplete threads in the circumferential direction. In EDM machining, machining is required by an electrode adapted to the discharge portion, and machining one by one and more accurate machining can be facilitated by decomposing the electrode teeth formed. The plurality of electrode teeth are distributed along the corresponding axial direction, so that the electrode teeth can be conveniently machined along the axial direction or in a fixed feed direction made by referring to a certain part of the electrode teeth, the machining efficiency can be improved, and the sharp angle edge can be conveniently machined. The electrode machining model serves as a machining target for the electrode blank 24 by the CNC machining center.
Step S200: electrode clamping: the electrode blank 24 is clamped to the CNC machining center by a clamp.
In this step, the jig preferably employs a 3R-Holder, and the brass blank is clamped by the 3R-Holder, which is a jig of 3R company, mainly for quick positioning, with repeated positioning accuracy of up to 0.002mm. The electrode is clamped by the 3R holder so as to better and more conveniently transfer the high precision of the electrode after being processed to the electric discharge machining. If the 3R clamp is not arranged, other clamping modes such as a vice and the like can be used, so long as the electrode machining requirements are met. The CNC machining center is a precise triaxial vertical machining center, and the electrode blank 24 is clamped on a machining center workbench of the CNC machining center through a 3R-Holder.
Step S300: programming the processing procedure: and (3) utilizing programming software to formulate machining procedures of electrode opening and electrode finishing which are matched with the electrode machining model.
In this step, the machining steps of the electrode roughening and electrode finishing are established, i.e., the machining steps that need to be performed by the CNC machining center.
Step S400: electrode processing: and the CNC machining center sequentially executes machining procedures of electrode roughing and electrode finishing, and a finished electrode with the characteristic of the thread-like shape 2 is obtained through machining.
In the step, the obtained finished electrode is in a shape matched with an electrode processing model, and the finished electrode can be used for processing a part blank in EDM processing to process a discharge part with the characteristic of the similar thread shape 2.
Referring to fig. 3-5, in an embodiment of the present application, in a step electrode design, the obtained electrode structure is adapted for CNC machining, including the following methods:
step S110: each electrode tooth is provided with a vertical surface participating in discharge, sharp angles or sharp angles are distinguished according to the shape of the electrode, a reinforcing circular arc is added on one side with the sharp angles or the sharp angles according to the actual condition of the target part 1, and a clearance abdication plane is formed on the electrode tooth, and then an R angle is formed and tangential with the tooth part.
In this step, each of the decomposed electrode teeth has a shape and only one vertical surface participating in the discharge in order to facilitate the feeding when machining the electrode. And distinguishing sharp angles or sharp angles according to the shape of the electrode, and adding a reinforcing circular arc beside the sharp angles or the sharp angles according to the actual condition of the part. The electrode teeth are not directly stretched when the clearance giving way is made, but the clearance giving way plane is made to be inverted with an R angle and tangent with the tooth part, so that a CNC cutter can be used to finish one-time accurate addition of the part of the electrode teeth which needs to participate in discharging, and the dimensional accuracy of the electrode teeth can be ensured. This provides high processing efficiency and reduces processing costs.
Referring to fig. 7-9, in one embodiment, the electrode roughening process includes the following steps:
step S310: adopting a cavity milling strategy, selecting a cutter D6-D8, and carrying out rough cutting on the electrode blank 24 to remove the allowance;
step S320: adopting a secondary rough cutting machining strategy, and selecting cutters D1-D3 to perform partial rough cutting;
step S330: adopting a contour machining strategy, and selecting a cutter of D0.3-D0.6 to perform local rough cutting;
step S340: and adopting a contour machining strategy, and selecting a ball cutter matched with the R angle 14 in the tooth part of the electrode tooth to perform partial rough cutting.
By such an electrode rough machining process, a structure that facilitates further finishing can be machined.
Further, in the electrode roughening processing step, the roughening margin is controlled to be not less than 0.05MM and not more than 0.07 MM. The tool for electrode thickening can be flexibly selected according to the processing equipment, so long as the shape allowance of the electrode teeth can be controlled between 0.05MM and 0.07 MM. The processing parameters can also be flexibly configured according to the respective processing environments.
Referring to fig. 10 and 11, in the embodiment of the present application, the electrode finishing process includes the following steps:
step S350: adopting a plane milling strategy, selecting a D2-D4 flat cutter, and finishing a vertical plane with four 6 weeks of abdication of each electrode tooth;
step S360: the electrode tooth thread shape 2 and other relevant surfaces are finished, and the relevant surfaces are processed and molded once.
Further, please refer to fig. 12 and 13, the finishing of the electrode tooth thread shape 2 and other related surfaces, which are to be formed by one-time processing, includes the following steps:
step S361: selecting a ball cutter slightly smaller than an R angle 14 in an electrode tooth part, adopting a processing strategy of area milling, setting a reciprocating feed non-steep cutting mode, and enabling the cutting direction to be down milling;
step S362: analyzing the shape of the electrode teeth to determine a cutting angle, wherein if the shape of the electrode teeth is an inclined plane and an arc surface, the cutting angle is designated to be parallel to the inclination direction of the threads, and the cutting direction is milled from one end of the electrode teeth to the other end of the electrode teeth; if the electrode tooth has a shape with an inclined surface, an arc surface and a vertical surface, the cutting angle is specified in a direction parallel to the vertical surface, the cutting direction starts milling from the opposite side of the vertical surface of the electrode tooth, mills from one end of the electrode tooth to the top of the vertical surface, then from the top of the vertical surface to the root of the vertical surface, and finally ends at the other end of the electrode tooth.
The purpose of such milling is to reduce sharp corners or sharp corner burrs due to the vertical surfaces on the electrode teeth, while also providing a margin support of 0.05MM to 0.07MM to avoid collapsing sharp corners when machining sharp corners or sharp corners on top of the vertical surfaces.
Further, as shown in fig. 3, regarding electrode surface control, the step size of the ball cutter during finishing determines the surface roughness of the electrode. The size of the R angle 14 in the electrode tooth part is different, the size of the selected cutter is different, and the step size of the specific ball cutter feed is also different. The relation of parameters such as rotating speed, feeding and cutting amount is provided based on the surface roughness requirement of a common electrode, and is shown in the table I. The amount of run down can be reduced appropriately if a higher electrode surface roughness is required, and the remaining parameters can remain unchanged. If the rotating speed of the machine tool is less than 30000rpm, corresponding processing parameters can be set according to the actual processing capacity of the machine tool, so long as the electrode surface requirement is met. Because the cutter is small, the influence of the service life of the cutter on the electrode quality is required to be paid attention to, and the limit of the service life of the cutter is reached, so that the cutter is suggested to be replaced by a new cutter in time.
Table-corresponding relation table of parameters such as rotation speed, feeding and cutting amount
| Electrode tooth portion inner R (mm) | Cutting tool | Lower cutter (mm) | Rotating speed (r/min) | Feed (mm) | Knife tool life (min) |
| 0.1 | φ0.2 | 0.010 | 30000 | 300 | 20 |
| 0.15 | φ0.3 | 0.015 | 29000 | 350 | 25 |
| 0.2 | φ0.4 | 0.020 | 28000 | 400 | 35 |
| 0.25 | φ0.5 | 0.025 | 27000 | 500 | 45 |
| 0.3 | φ0.6 | 0.030 | 26000 | 550 | 60 |
In a specific implementation process, after the machining process of electrode finishing, the machining process of electrode finishing is performed again, and the service life of the ball cutter is doubled in the machining process. If the size and the burr are required to be further controlled, the near burr-free state can be achieved, the finishing process can be executed after finishing the finishing process, and the service life of the finished ball cutter can be doubled on the basis of the service life of the table cutter. Finally, the quality is improved by using an ultra-high-performance precise triaxial vertical machining center (such as a summer mils 400) to perform the machining.
In a specific practical application process, the target part 1 is provided with two discharge parts, the two discharge parts are respectively positioned at two ends of the target part 1, the discharge parts are arc-shaped groove structures with the characteristics of the similar thread shape 2, the electrode teeth are sheet-shaped and are provided with tooth parts and end plane matched with the discharge parts, and the end plane of the electrode teeth is overlapped with the electrode platform and is arranged on the electrode platform.
Correspondingly, two rows of multiple groups of electrode teeth are arranged on the electrode table, one group of electrode teeth of each row of electrode teeth can be used for machining a complete thread-like shape 2 on a part blank through EDM machining, and EDM machining of batch target parts 1 can be realized through arranging multiple groups.
Referring to fig. 6, in the embodiment of the present application, two adjacent electrode teeth are arranged on the electrode table at a distance suitable for electric discharge machining.
The distance suitable for electrical discharge machining is the PITCH distance, which is also understood to be a distance of movement of the finished electrode during machining. When EDM is used for discharging and processing the large electrode 22, one electrode tooth is firstly used for processing, so that the decomposed electrode teeth are distributed according to a certain PITCH distance according to the requirement of the number of parts on the number of electrode teeth to form the large electrode 22, and the large electrode 22 is an electrode processing model. Such large electrodes 22 are not longer than 120MM in size and more than 60MM in width, and if they are longer and wider than this, the other electrode is considered to be arranged because too long and too wide deform more after the electrode processing is completed, which affects the dimensional accuracy of the electrode. The PITCH distance is determined according to the position of the part and the size of the tool during machining of the electrode according to the thread-like characteristics, and the principle is that the large electrode 22 does not hurt the part in the moving and using process, and the machining is convenient. The design can improve the accuracy of the relative position between the electrode teeth and the teeth, can reduce the auxiliary time for electrode replacement in the electrode discharge machining, and can continuously machine the electrode teeth if the electrode teeth are damaged and replaced by the same electrode teeth until the electrode discharge position meets the product requirement, and can replace the electrode teeth to machine other discharge positions until the part features are completely machined.
The electrode machining method with the characteristic of the thread-like shape 2 has the following beneficial effects:
starting from the electrode design, the electrode shape obtained from the discharge part with the characteristic of the similar thread shape 2 of the target part 1 is decomposed, electrode teeth which are convenient to process by a CNC processing center can be obtained after decomposition, the electrode teeth obtained through decomposition can be convenient to process sharp corners or sharp corners, auxiliary bodies such as vertical surfaces and reinforced circular arcs are adopted, and the processing procedures of electrode rough cutting and electrode finish processing are sequentially carried out in an arrangement mode which is convenient to feed in the same fixed direction, so that burrs and thinner shapes of the sharp corners or sharp corners of the electrode can be controlled in an acceptable range, a burr-free state can be achieved, and meanwhile, the problems that the surface finish degree of the electrode is good and the sizes of the sharp corners and the sharp corners are accurate are solved.
Preferred embodiments:
referring to fig. 1-13, in order to solve the problem that the sharp angle or sharp angle burr and the shape of the electrode of the part with the thread-like shape 2 are too thin and extremely easy to damage, we start with the design of the electrode, add an auxiliary body with the sharp angle or sharp angle edge, feed in a fixed direction during the writing and processing of the tool path, and finally control the sharp angle or sharp angle burr and the thinner shape of the electrode in an acceptable range, and can also reach a state without the burr. The method solves the problems of good surface finish of the electrode and accurate sharp angle and sharp angle dimensions.
The part with the thread-like shape 2 has the advantages that the thread-like shape 2 with smaller diameter is difficult to mill or grind by using a lathe, high-end processing equipment is needed, the processing cost is high, the EDM (electronic discharge machining) manufacturing cost is reduced greatly, and the part is convenient to popularize and apply in the manufacturing industry. And the electrode for discharging is processed by a triaxial vertical CNC processing center. Since smaller diameter thread-like features require very small electrode teeth, and corresponding CNC machining tools, a 0.2MM diameter tool is least likely to be used, and the required CNC machining center speed is at least 30000rpm.
The adopted technical scheme is as follows:
1. the electrode design (completed by three-dimensional software), the 3D part is opened in the three-dimensional software, the discharging part of the part is taken out from the 3D part by the software function, the shape of the electrode taken out at the moment is possibly unsuitable for CNC cutter processing, the electrode is decomposed into electrode teeth which can be processed by CNC, as shown in figure 2, one discharging part can be decomposed into three electrode teeth, namely, electrode tooth one 3, electrode tooth two 4 and electrode tooth three 5, and the electrode teeth decomposed by the other discharging part are electrode tooth four 6, electrode tooth five 7 and electrode tooth six 8; several separated electrode teeth are separated by EDM and electric discharge machining to finally form a complete thread-like feature on the part. To facilitate the feeding of the electrode during machining, each of the split electrode teeth has a shape with only one vertical surface involved in the discharge, as shown in fig. 3. And then the sharp angle or the sharp angle is distinguished according to the shape of the electrode, as shown in fig. 3, and a reinforcing circular arc is added beside the sharp angle or the sharp angle according to the actual condition of the part, as shown in fig. 4. When the clearance giving way of the electrode teeth is made, the electrode teeth are not directly stretched, but the clearance giving way plane is made to be inverted by an R angle and tangent with the teeth, as shown in fig. 5, so that the part of the electrode teeth needing to participate in discharging can be precisely added at one time by using a CNC cutter, and the dimensional accuracy of the electrode teeth can be ensured. Thus, the processing efficiency can be improved, and the processing cost can be reduced. In EDM, when the large electrode 22 is used for discharge machining, one electrode tooth is used for machining, so that the decomposed electrode teeth are arranged according to the requirement of the number of parts to the number of electrode teeth and are arranged according to a certain PITCH distance to form the large electrode 22, as shown in fig. 6. It is recommended that such large electrodes 22 be no longer than 120MM in size and no longer than 60MM in width, and if they are greater than this length and width, it is considered to arrange another electrode because too long and too wide deform more after the electrode is finished, which would affect the dimensional accuracy of the electrode. The PITCH distance is determined according to the position of the part and the size of the tool during machining of the electrode according to the thread-like characteristics, and the principle is that the large electrode 22 does not hurt the part in the moving and using process, and the machining is convenient. The design can improve the accuracy of the relative position between the electrode teeth and the teeth, and can also reduce the auxiliary time for electrode replacement in the electrode discharge machining, if the electrode teeth are damaged, the next same electrode teeth are replaced for continuous machining until the electrode discharge position meets the product requirement, the other electrode teeth are replaced for machining other discharge positions until the part features are completely machined.
The electrode teeth after the decomposition of the two discharging parts of the target part 1 have the same structural characteristics, and the electrode teeth I3, the electrode teeth II 4 and the electrode teeth III 5 belong to one discharging part, wherein the electrode teeth I3 are provided with a tooth sharp angle 9, a tooth inclined surface III 16, an in-tooth R angle 14, a reinforcing arc I18 and a vertical surface 17 of a first tooth part which participates in discharging, the electrode teeth II are provided with a tooth utilizing angle 10, a tooth inclined surface I11, an in-tooth R angle 14, a vertical surface 15 of a second tooth part which participates in discharging and a reinforcing arc II 19, and the electrode teeth III 5 are provided with a tooth cambered surface 12 and a tooth inclined surface II 13; each electrode tooth is provided with a clearance plane 20 and a yielding R21; meanwhile, the large electrode 22 is formed with an electrode Z-direction reference 23,
2. and (3) clamping the electrode processing, namely clamping the brass blank by using a 3R-Holder, wherein the 3R-Holder is a fixture of a 3R company and is mainly used for quick positioning, and the repeated positioning accuracy is up to 0.002mm. The electrode is clamped by the 3R-holder to better and more conveniently transfer the high precision of the electrode after being processed to the electric discharge machining. If the 3R clamp is not arranged, other clamping modes such as a vice and the like can be used, so long as the electrode machining requirements are met.
3. Electrode coarsening (programming is completed by programming software), firstly, coarsening electrode wool in a large amount to remove allowance, and coarsening by selecting larger cutters (such as D8 and D6), wherein a cavity milling strategy is used as shown in FIG. 7; and selecting smaller cutters (such as D3 and D1) for partial roughing, and using a secondary roughing machining strategy as shown in figure 8. Step three, selecting smaller cutters (such as D0.5) for local coarsening, and using a contour machining strategy as shown in FIG. 8; and fourthly, selecting a ball cutter (such as R0.2) which is close to the R angle 14 in the electrode tooth part to be partially thickened, and using a contour machining strategy as shown in fig. 3 and 9. The margin of the four-step rough cutting is controlled to be not less than 0.05MM and not more than 0.07 MM. The tool for electrode thickening can be flexibly selected according to the processing equipment, so long as the shape allowance of the electrode teeth can be controlled between 0.05MM and 0.07 MM. The processing parameters can also be flexibly configured according to the respective processing environments.
4. Electrode finish machining (programming is finished by programming software), a finishing cutter can be moved after finishing rough cutting, a larger flat cutter (such as D3) is selected to finish the vertical planes of the peripheral abdication of the shape of each electrode tooth, and a plane milling strategy is adopted, as shown in fig. 10; in the second step, the electrode tooth thread form 2 and other relevant surfaces are finished and formed once, as shown in fig. 11. Firstly, a ball cutter (R0.2) which is slightly smaller than an R angle 14 (shown in figure 3) in an electrode tooth part is selected, then a machining strategy of region milling is selected, a reciprocating feed non-steep cutting mode is set, the cutting direction is forward milling, and the step pitch is applied to a part. Finally, analyzing the shape of the electrode teeth to determine a cutting angle, if the shape of the electrode teeth is an inclined plane and an arc surface, the cutting angle is designated in a direction parallel to the inclination of the threads, and the cutting direction is finished from one end of the electrode teeth to the other end of the electrode teeth, as shown in fig. 12; if the electrode teeth are shaped with an inclined surface and an arc surface and also with a vertical surface, the cutting angle is specified in a direction parallel to the vertical surface, and the cutting direction is to start milling from the opposite side of the vertical surface of the electrode teeth, namely, the tool path is to be milled from one end of the electrode teeth to the top of the vertical surface, then from the top of the vertical surface to the root of the vertical surface, and finally, to end at the other end of the electrode teeth, as shown in fig. 13. The purpose of such milling is to make the sharp corners or sharp corners burrs due to the vertical surfaces on the electrode teeth less, while at the same time there is a margin support of 0.05MM to 0.07MM to avoid collapsing the sharp corners when machining to the sharp corners or sharp corners at the top of the vertical surfaces.
5. And controlling the surface of the electrode, and determining the surface roughness of the electrode according to the step pitch of the ball cutter during finish machining. As the R angle 14 in the electrode tooth portion varies in size, the size of the selected tool varies, and the step size of the specific ball cutter feed varies as shown in fig. 3. The parameters of the rotating speed, feeding and cutting amount are provided based on the surface roughness requirement of the common electrode. The amount of run down can be reduced appropriately if a higher electrode surface roughness is required, and the remaining parameters can remain unchanged. If the rotating speed of the machine tool is less than 30000rpm, corresponding processing parameters can be set according to the actual processing capacity of the machine tool, so long as the electrode surface requirement is met. Because the cutter is small, the influence of the service life of the cutter on the electrode quality is required to be paid attention to, and the limit of the service life of the cutter is reached, so that the cutter is suggested to be replaced by a new cutter in time.
6. The control of the electrode size and the burrs, such as processing according to the method, can be controlled to a good state, if the size and the burrs are further controlled, the near burr-free state can be achieved, the finishing process can be executed after finishing the finishing, and the service life of the finished ball cutter can be doubled on the basis of the service life of the cutter. Finally, the quality is improved by using an ultra-high-performance precise triaxial vertical machining center (such as a summer MILL-S400) to perform the machining.
7. The motion mode is that a precise triaxial vertical machining center is selected for machining, and the rotating speed is more than 30000rpm. The electrode is fixed on a workbench of the machining center through a 3R-Holder clamp. The main shaft of the machine tool rotates, and the milling of the electrode is realized through the movement of three shafts of the machine tool.
The beneficial effects are that: the processing method for removing the sharp corner burrs of the electrode solves a series of problems that the shape of the similar threaded electrode is easy to damage, the size is difficult to ensure and the surface roughness of the electrode is poor because of more burrs, and provides a solid foundation for EDM processing of the similar parts. A wider space is opened for the processing of the high-quality parts at present.
Finally, it should be noted that: the foregoing description is only of the preferred embodiments of the invention and is not intended to limit the scope of the invention. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present invention should be included in the protection scope of the present invention.
Claims (10)
1. An electrode processing method with thread-like characteristics is characterized in that: the method comprises the following steps:
electrode design: acquiring an electrode shape matched with a discharge part of at least one target part with the aid of three-dimensional software from the discharge part with thread-like characteristics, decomposing the electrode shape into a plurality of electrode teeth suitable for CNC machining center machining along the axial direction of the electrode shape, wherein the electrode teeth are provided with tooth parts, the tooth parts of each electrode tooth can jointly form the electrode shape, then uniformly arranging each electrode tooth belonging to the same electrode shape on an electrode table along the axial direction in sequence, and taking a structure formed by the electrode table and each electrode tooth as an electrode machining model;
electrode clamping: clamping the electrode blank in a CNC machining center through a clamp;
programming the processing procedure: utilizing programming software to formulate an electrode rough cutting and electrode finish machining working procedure matched with the electrode machining model;
electrode processing: sequentially executing machining procedures of electrode roughing and electrode finishing by a CNC machining center, and obtaining a finished electrode with thread-like characteristics through machining;
wherein in the step electrode design, the obtained electrode structure is suitable for CNC machining, comprising the following steps:
each electrode tooth is provided with a vertical surface participating in discharge, sharp angles or sharp angles are distinguished according to the shape of the electrode, a reinforcing circular arc is added on one side with the sharp angles or the sharp angles according to the actual condition of a target part, a clearance abdication plane is formed on the electrode tooth, and then an R angle is chamfered and tangential with the tooth part.
2. A method of machining an electrode with thread-like features as claimed in claim 1, wherein: the electrode rough cutting processing procedure comprises the following steps:
adopting a cavity milling strategy, selecting a D6-D8 cutter, and carrying out rough cutting on the electrode blank to remove the allowance;
adopting a secondary rough cutting machining strategy, and selecting cutters D1-D3 to perform partial rough cutting;
adopting a contour machining strategy, and selecting a cutter of D0.3-D0.6 to perform local rough cutting;
and adopting a contour machining strategy, and selecting a ball cutter matched with the R angle in the tooth part of the electrode tooth to perform partial rough cutting.
3. A method of machining an electrode with thread-like features as claimed in claim 2, wherein: in the electrode roughening processing step, the roughening margin is controlled to be not less than 0.05MM and not more than 0.07 MM.
4. A method of machining an electrode with thread-like features according to any one of claims 1-3, characterized in that: the electrode finishing machining process comprises the following steps of:
adopting a plane milling strategy, selecting a D2-D4 flat cutter, and finishing the vertical planes of the peripheral abdication of each electrode tooth;
and finishing the thread shape of the electrode teeth and other related surfaces, wherein the related surfaces are required to be processed and molded at one time.
5. A method of machining an electrode with thread-like features as claimed in claim 4, wherein: the method for finishing the thread shape and other related surfaces of the electrode teeth comprises the following steps of:
selecting a ball cutter smaller than an R angle in an electrode tooth part, adopting a processing strategy of area milling, setting a reciprocating feed non-steep cutting mode, and enabling the cutting direction to be down milling;
analyzing the shape of the electrode teeth to determine a cutting angle, wherein if the shape of the electrode teeth is an inclined plane and an arc surface, the cutting angle is designated to be parallel to the inclination direction of the threads, and the cutting direction is milled from one end of the electrode teeth to the other end of the electrode teeth; if the electrode tooth has a shape with an inclined surface, an arc surface and a vertical surface, the cutting angle is specified in a direction parallel to the vertical surface, the cutting direction starts milling from the opposite side of the vertical surface of the electrode tooth, mills from one end of the electrode tooth to the top of the vertical surface, then from the top of the vertical surface to the root of the vertical surface, and finally ends at the other end of the electrode tooth.
6. The method for machining an electrode with a thread-like feature of claim 5, wherein: in the machining procedure of electrode finish machining, when R in an electrode tooth part is 0.1mm, a cutter with the diameter of D0.2 is selected, the cutter setting amount is 0.01mm, the machine tool rotating speed is 30000R/min, the feeding amount is 300mm, and the service life of the cutter is 20min;
when R in the electrode tooth part is 0.15mm, a cutter with the diameter of D0.3 is selected, the cutter setting amount is 0.015mm, the rotating speed of a machine tool is 29000R/min, the feeding amount is 350mm, and the service life of the cutter is 25min;
when R in the electrode tooth part is 0.2mm, a cutter with the diameter of D0.4 is selected, the cutter setting amount is 0.02mm, the rotating speed of a machine tool is 28000R/min, the feeding amount is 400mm, and the service life of the cutter is 35min;
when R in the electrode tooth part is 0.25mm, a cutter with the diameter of D0.5 is selected, the cutter setting amount is 0.025mm, the rotating speed of a machine tool is 27000R/min, the feeding amount is 500mm, and the service life of the cutter is 45min;
when R in the electrode tooth part is 0.3mm, a cutter with the diameter of D0.6 is selected, the cutter setting amount is 0.03mm, the rotating speed of a machine tool is 26000R/min, the feeding amount is 550mm, and the service life of the cutter is 60min.
7. The method for machining an electrode with a thread-like feature of claim 6, wherein: after the electrode finishing machining process, the electrode finishing machining process is performed once again.
8. A method of machining an electrode with thread-like features as claimed in claim 1, wherein: the target part is provided with two discharging parts, the two discharging parts are respectively positioned at two ends of the target part, each discharging part is of an arc-shaped groove structure with a thread-like characteristic, the electrode teeth are sheet-shaped and are provided with tooth parts and end planes matched with the discharging parts, and the end planes of the electrode teeth are arranged on the electrode table in a superposition manner with the electrode table.
9. A method of machining an electrode with thread-like features as claimed in claim 8, wherein: two adjacent electrode teeth are arranged on the electrode table at a distance suitable for electric discharge machining.
10. A method of machining an electrode with thread-like features as claimed in claim 8, wherein: the discharge parts at two ends of the target part can be respectively decomposed into three electrode teeth, the electrode teeth of the two discharge parts have the same structure and comprise electrode teeth I, electrode teeth II and electrode teeth III, the electrode teeth I are provided with tooth sharp angles, tooth inclined planes III, tooth inner R angles and reinforcing circular arcs I and vertical surfaces of the first tooth parts participating in discharge, the electrode teeth II are provided with tooth sharp angles, tooth inclined planes I, tooth inner R angles and vertical surfaces of the second tooth parts participating in discharge and reinforcing circular arcs II, and the electrode teeth III are provided with tooth cambered surfaces and tooth inclined planes II; and each electrode tooth is provided with a clearance plane and a abdication.
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