CN116900650A - Processing method of thin and high straight cylindrical electrode - Google Patents
Processing method of thin and high straight cylindrical electrode Download PDFInfo
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- CN116900650A CN116900650A CN202311168700.7A CN202311168700A CN116900650A CN 116900650 A CN116900650 A CN 116900650A CN 202311168700 A CN202311168700 A CN 202311168700A CN 116900650 A CN116900650 A CN 116900650A
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- 238000003672 processing method Methods 0.000 title claims abstract description 10
- 238000003754 machining Methods 0.000 claims abstract description 70
- 238000005520 cutting process Methods 0.000 claims abstract description 46
- 238000000034 method Methods 0.000 claims abstract description 26
- 238000000227 grinding Methods 0.000 claims abstract description 10
- 238000003801 milling Methods 0.000 claims description 13
- 230000003746 surface roughness Effects 0.000 claims description 4
- 229910001369 Brass Inorganic materials 0.000 claims description 3
- 239000010951 brass Substances 0.000 claims description 3
- 238000004519 manufacturing process Methods 0.000 claims 1
- 238000012545 processing Methods 0.000 abstract description 17
- 229910000831 Steel Inorganic materials 0.000 description 3
- 230000009286 beneficial effect Effects 0.000 description 3
- 238000013461 design Methods 0.000 description 3
- 238000001514 detection method Methods 0.000 description 3
- 238000009760 electrical discharge machining Methods 0.000 description 3
- 239000010959 steel Substances 0.000 description 3
- 238000010586 diagram Methods 0.000 description 2
- 238000004891 communication Methods 0.000 description 1
- 238000007599 discharging Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000007730 finishing process Methods 0.000 description 1
- 230000003993 interaction Effects 0.000 description 1
- 238000012797 qualification Methods 0.000 description 1
- 239000000725 suspension Substances 0.000 description 1
- 238000012546 transfer Methods 0.000 description 1
Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
- B23P15/00—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Electrical Discharge Machining, Electrochemical Machining, And Combined Machining (AREA)
Abstract
The invention discloses a processing method of a thin high straight cylindrical electrode, which comprises the following steps: clamping; rough machining, namely machining a rough geometric part, a reference seat and a blank seat on an electrode blank; finish machining, namely performing finish machining on the thick-open geometric component in a spiral cutting mode to enable the thick-open geometric component to form thin and high straight cylindrical electrode teeth; wherein the tool treatment used for finishing includes: a straight cylindrical cutter is selected, and the cutter edge of the cutter is ground to form an annular clearance section and an annular cutting edge section. The invention processes and shapes the thin and high straight cylindrical electrode with the ratio of the height to the diameter reaching 5 to 15 times, and meets the processing requirement, and the processing method breaks through the limit of the conventional lathe cutting or grinding processing method, solves the processing bottleneck of the thin and high straight cylindrical electrode, does not need too high requirement on a machine tool, and has the advantages of cheap required cutter, low processing cost, high processing efficiency and convenient popularization and application.
Description
Technical Field
The invention belongs to the technical field of electrode machining, and particularly relates to a machining method of a thin and high straight cylindrical electrode.
Background
During the design of plastic molds, there are many straight cylindrical features (e.g., pin holes, cavities for circular inserts, etc.) that are cylindrical, straight from top to bottom, blind, and open, and require a process line precision of 0 to +0.005MM. This straight cylindrical feature, large but shallow diameter allows CNC direct machining, and small and deep diameter requires EDM electrical discharge machining. If the diameter is small and the specific energy of the height (H) to the diameter (D) is 5 to 15 times, the electrode for EDM discharge designed in this way is difficult to process, and the electrode requires good surface roughness and high concentricity, and simultaneously ensures roundness. Machining such thin and high straight cylindrical electrodes is a bottleneck in machining, and is difficult to accomplish by conventional lathe cutting or grinding machining methods, which require multiple times of debugging, are time-consuming to operate and have high error rate, resulting in low qualification rate of the machined products and difficult mass machining.
Disclosure of Invention
The invention aims to provide a processing method of a thin and high straight cylindrical electrode, which is used for solving the problems in the prior art.
In order to achieve the above purpose, the present invention adopts the following technical scheme: a processing method of a thin and high straight cylindrical electrode comprises the following steps:
step A, clamping, namely positioning and mounting an electrode blank on a machining part of a machine tool through a clamping tool;
step B, rough machining, namely machining a rough geometric part, a reference seat and a blank seat on the electrode blank, wherein the rough geometric part, the reference seat and the blank seat are sequentially connected from top to bottom, the rough geometric part is in a tower shape with a small upper part and a large lower part, and the rough geometric part has a pattern draft angle A;
step C, finish machining, namely finish machining the thick-open geometric component in a spiral cutting mode to enable the thick-open geometric component to form thin and high straight cylindrical electrode teeth; wherein the tool treatment used for finishing includes: the method comprises the steps of selecting a straight cylindrical cutter, grinding the cutter to form an annular clearance section on the cutter, wherein annular cutting edge sections and cutter bar sections are respectively arranged at two ends of the annular clearance section, and the total length of the annular clearance section and the annular cutting edge sections is larger than that of the rough geometrical component.
As an optional implementation manner of the foregoing technical solution, a difference between a radius of the annular cutting edge section and a radius of the annular clearance section is not less than 0.3mm.
As an optional implementation manner of the foregoing technical solution, a length of the annular cutting edge section is not greater than 1mm.
As an optional implementation manner of the above technical solution, a difference between the outer diameter of the cutter bar section and the outer diameter of the annular cutting edge section is not less than 0.01mm.
As an alternative embodiment of the foregoing solution, in step B, a 3D model of the open-coarse geometrical component is created by programming software before the roughing is performed, the 3D model of the open-coarse geometrical component completely encasing the electrode teeth.
As an optional implementation manner of the above technical solution, in the step B, the rough machining selects cavity milling, the rough machining selects the rough machining geometric component for proceeding, and the finish milling is selected, and the rough machining leaves a rough machining allowance.
As an alternative embodiment of the foregoing technical solution, the draft angle a of the open-coarse geometric part is in a range of 1.8 ° to 2.4 °.
As an alternative implementation mode of the technical scheme, in the step B, the rotating speed of the clamping tool in the rough machining process is 5000-6000 rpm, the cutter feeding amount is 0.4-0.6 mm, the rough cutting allowance of 0.25-0.4 mm is reserved, and the feeding amount is 2500-3000 mm.
As an optional implementation manner of the foregoing technical solution, in step a, positioning and mounting the electrode blank on a machining portion of a machine tool by using a clamping tool includes: the electrode blank is clamped and fixed on a workbench of the triaxial vertical machining center through the 3R clamping fixture, and the triaxial vertical machining center is used as a machine tool to machine the electrode blank in a triaxial machining mode.
As an alternative embodiment of the foregoing solution, in step C, the offset surface function of the programming software modeling module is used to reduce the portion of the electrode teeth by a distance of one discharge spark gap before finishing, so as to avoid errors generated by the discharge spark gap.
As an alternative embodiment of the foregoing solution, in step C, the finishing the rough geometric component by spiral cutting includes: selecting a curved surface area driving method, and adopting a spiral cutting mode to carry out forward milling on the electrode teeth; the rotating speed of the clamping tool is 5000-6000 rpm, the cutter feeding amount is 0.03-0.10 mm, and the feeding amount is 500-1100 mm.
As an optional implementation manner of the technical scheme, the method further comprises a step D of detecting the surface roughness, the shape and the concentricity of the electrode after finishing so as to judge whether the electrode is qualified or not.
As an optional implementation manner of the foregoing technical solution, step D further includes: and (3) repeating the step A, the step B and the step C by adjusting the cutting parameters for unqualified electrodes until the machining is qualified.
As an alternative embodiment of the foregoing technical solution, the electrode blank is a brass blank.
The beneficial effects of the invention are as follows:
the invention provides a processing method of a thin and high straight cylindrical electrode, which is used for processing and forming the thin and high straight cylindrical electrode with the ratio of the height to the diameter of 5-15 times and meeting the processing requirement.
Drawings
FIG. 1 is a schematic perspective view of a thin, tall, straight cylindrical electrode in one embodiment of the invention;
FIG. 2 is a schematic diagram of the front structure of a thin, tall, straight cylindrical electrode in one embodiment of the present invention;
FIG. 3 is a schematic view of an electrode blank with increased draft in accordance with one embodiment of the present invention;
FIG. 4 is a schematic view of the structure of an untreated cutter according to an embodiment of the present invention;
FIG. 5 is a schematic view showing the structure of a grinding tool according to an embodiment of the present invention;
FIG. 6 is a schematic view of a tool-to-electrode contact process in accordance with one embodiment of the invention;
fig. 7 is a diagram of a helical cutting path in one embodiment of the present invention.
In the figure: 1-opening a thick geometric part; 2-a reference base; 3-blank seat; 4-electrode teeth; 5-cutting tool; 6-an annular clearance section; 7-an annular cutting edge section; 8-cutter bar section.
Detailed Description
The following describes specific embodiments of the present invention in detail with reference to the drawings.
As shown in fig. 1 to 7, the present embodiment provides a method for processing a thin high straight cylindrical electrode, including the steps of:
(1) Clamping, namely clamping a 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 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.
(2) Electrode rough opening 3D geometric part processing (completed by programming software), a 3D model of the rough opening geometric part 1 is established by the programming software, the electrode teeth 4 are completely wrapped by the 3D model of the rough opening geometric part 1, the height of the electrode teeth 4 is H, the diameter of the electrode teeth 4 is D, and the ratio of the height H of the electrode teeth 4 to the diameter D is generally 5-15. During specific treatment, the thin and high straight cylindrical electrode teeth 4 are added with a draft angle A (namely the inclination angle of the side wall of the electrode teeth 4), the added draft angle A is generally kept between 1.8 degrees and 2.4 degrees, the thick geometric component 1 is opened to form a pagoda shape with a small upper part and a large lower part, and the thick geometric component 1 completely covers the whole electrode teeth 4. The increased draft angle A has the effect of improving the strength of the electrode teeth 4 in the rough machining process, and can ensure that the electrode is not broken, deformed and damaged in the rough machining process.
(3) And (3) rough machining, namely placing the 3R Holder with the electrode blank clamped on a 3R base of a machine tool, setting a machining zero position, preparing a required cutter 5 and the length of the cutter 5, and operating a rough machining program to machine, wherein the rough geometrical component 1, the reference seat 2 and the blank seat 3 are machined on the electrode blank, and the rough geometrical component 1, the reference seat 2 and the blank seat 3 are sequentially connected from top to bottom. Roughing program cutting parameters (done by means of programmed software): and (3) performing rough machining, namely selecting cavity milling, performing rough machining, selecting the rough-machined geometric part 1 subjected to increased die drawing, and selecting finish milling, wherein a certain rough machining allowance is reserved in rough machining. The tool 5 can be considered comprehensively according to the height of the electrode teeth 4 and the length of the tool 5, the larger the diameter of the tool 5 is, the longer the total length of the tool 5 is, the longer the blade which can be used for cutting is, the total length of the tool 5 of phi 6 is 55MM for cutting length 35MM, the total length of the tool 5 of phi 8 is 70MM for cutting length 45MM, the total length of the tool 5 of phi 10 is 80MM for cutting length 55MM, and the total length of the tool 5 of phi 12 is 100MM for cutting length 65MM. Since the tools 5 and the machine tools of the respective factories are different, the tool selecting and the tool setting amounts are comprehensively considered, and in any case, the reliability of the selected tools 5 during machining is ensured. The specific processing parameters of the cutter 5 selected for rough processing are shown in the following table:
(4) Electrode finishing 3D geometry processing (done by means of programming software) reduces the part of the electrode teeth 4 by one discharge spark gap distance to ensure that the finishing program finishes the number in zero 3D. The discharge spark gap is determined when the electrode is designed and marked on an electrode drawing, the discharge spark gap can be buckled according to the drawing mark, and the discharge spark gap can be removed by using the function of a bias surface in a programming software modeling module in specific operation, so that the error generated by the discharge spark gap is avoided.
(5) The finished tool 5 is selected for treatment with the tool 5 prior to use, including the following steps.
S1, selecting a cutter 5, wherein the cutter 5 can refer to the rough machining size, selecting a flat cutter for machining, and the cutter 5 has good cutter point and good machinability, and generally, the cutter 5 is beneficial to selecting sharp white steel. The white steel blade is selected because the white steel blade is sharper and sharper than the carbide blade. The electrode with too high teeth is selected as a large knife. Because the electrode teeth 4 are high, the suspension length of the machined tool 5 can be long when the tool 5 is clamped, so that the rigidity of the tool 5 in the cutting motion process is fully considered. The flat knife is mainly used for reducing transverse cutting force in the cutting process and ensuring that the electrode teeth 4 are not damaged by force. Also, attention is paid to the problem of wear of the tool 5, and a new tool must be replaced if the machining time exceeds the normal machining time. The cutter 5 comprises a blade and a cutter bar, the diameter of the blade is D, the diameter of the cutter bar is D, and the total length of the blade and the cutter bar is C.
S2, processing before using the cutter 5, when the cutter 5 is selected, grinding the selected cutter 5, and grinding the cutting edge and the cutter bar to form an annular clearance section 6 on the cutter 5, wherein the annular cutting edge section 7 and the cutter bar section 8 are respectively arranged at two ends of the annular clearance section 6, and the total length M of the annular clearance section 6 and the annular cutting edge section 7 is larger than the length of the rough geometrical component 1 by about 2mm.
Wherein, the difference S between the radius of annular blade section 7 and the radius of annular clearance section 6 is not less than 0.3mm, and the length L of annular blade section 7 is not more than 1mm, and the difference between the external diameter D of cutter arbor section 8 and external diameter D of annular blade section 7 is not less than 0.01mm. For the selected cutter 5, the outer diameter of the cutter 5 is required to be ground by a grinding wheel to be small by 0.3mm, an annular clearance section 6 is formed after grinding a small part, the part of the cutter edge which is not ground is an annular cutting edge section 7, and the length of the annular cutting edge section 7 is 1.0mm, so that only the annular cutting edge section 7 with the length of 1.0mm is always contacted with the rough geometrical component 1 in the whole finishing process.
Because the electrode teeth 4 to be machined are straight cylinders, the cutter 5 is also straight cylinders, and the side edge of the cutter 5 is always contacted with the straight cylinder electrode during finish machining, the cutter 5 and the electrode can be sprung due to the overlarge contact surface, and the shape of the straight cylinder electrode can be sprung. Therefore, the invention designs the annular clearance section 6, and the cutter 5 is sequentially provided with the cutter bar section 8, the annular clearance section 6 and the annular cutting edge section 7, wherein the length of the annular cutting edge section 7 is smaller than that of the cutter bar section 8. The purpose of the processing tool 5 is to reduce the contact surface between the tool 5 and the electrode, reduce the contact force, avoid the milling of the tool 5 to damage the workpiece, and prevent the tool 5 from bouncing to damage the electrode. In addition, the design of the annular clearance section 6 enables the cutter 5 and the electrode to form a clearance interval, and better chip removal can be achieved.
The specific machining parameters of the cutter 5 selected for finish machining are shown in the following table:
(6) The finished tool 5 is selected to be processed with the tool 5 before use, the finished tool selects a curved surface area driving method to process, a spiral cutting mode milling is adopted, a direct milling is arranged, and the whole direct milling is finished at one time.
(7) The motion mode is that a precise triaxial vertical machining center is selected for machining, and the rotating speed is more than 5000 rpm. The electrode is fixed on a workbench of a machining center through a 3R Holder, the workbench controls the X axis to move left and right, a main shaft of the machining center rotates and controls the Y axis and the Z axis to move back and forth and up and down.
(8) After the electrode is processed, detection is performed. The electrode was removed from the 3R base along with the 3R Holder. Firstly, whether the surface roughness meets the requirement is checked, then the projector is used for detecting the shape and concentricity, and three-coordinate automatic detection can be also performed. And after the detection is qualified, carrying out an electrode discharging process on the electrode and the 3R Holder together. And if the machining is not qualified, adjusting the cutting parameters, and repeating the machining until the machining is qualified. If the 3R holder is not available, the processing is carried out in the normal processing flow.
The invention provides a processing method of a thin and high straight cylindrical electrode, which is used for processing and forming the thin and high straight cylindrical electrode with the ratio of the height to the diameter of 5-15 times and meeting the processing requirement.
The method can realize the computer digital control precision machining (CNC machining) of the thin and high straight cylindrical electrode, greatly improves the machining efficiency, is more intelligent than the traditional lathe cutting or grinding machining, has simpler operation, reduces manual operation, greatly saves the machining cost, and is beneficial to popularization and application in the whole plastic mould industry.
In the description of the present invention, the terms "mounted," "connected," "secured," and the like are to be construed broadly and may be fixedly connected, detachably connected, or integrally formed; may be a mechanical or electrical connection; may be directly connected or indirectly connected through an intermediate medium, and may be in communication with the inside of two elements or in interaction with the two elements, the specific meaning of the terms being understood by those skilled in the art. Furthermore, the particular features, structures, etc. described in the examples are included in at least one embodiment and those of skill in the art may combine features of different embodiments without contradiction. The scope of the present invention is not limited to the above-described specific embodiments, and embodiments which can be suggested to those skilled in the art without inventive effort according to the basic technical concept of the present invention are all within the scope of the present invention.
Claims (10)
1. The processing method of the thin and high straight cylindrical electrode is characterized by comprising the following steps of:
step A, clamping, namely positioning and mounting an electrode blank on a machining part of a machine tool through a clamping tool;
step B, rough machining, namely machining a rough geometric part (1), a reference seat (2) and a blank seat (3) on an electrode blank, wherein the rough geometric part (1), the reference seat (2) and the blank seat (3) are sequentially connected from top to bottom, the rough geometric part (1) is in a tower shape with a small upper part and a large lower part, and the rough geometric part (1) has a draft angle A;
step C, finish machining, namely finish machining the thick-open geometric component (1) in a spiral cutting mode to enable the thick-open geometric component (1) to form thin and high straight cylindrical electrode teeth (4); wherein the tool (5) process used for finishing comprises: selecting a straight cylindrical cutter (5), performing grinding treatment on the cutter (5), forming an annular clearance section (6) on the cutter (5), respectively arranging an annular cutting edge section (7) and a cutter bar section (8) at two ends of the annular clearance section (6), wherein the total length of the annular clearance section (6) and the annular cutting edge section (7) is larger than the length of the rough geometrical component (1).
2. The method of machining a slim, high, straight cylindrical electrode according to claim 1, characterized in that the difference between the radius of the annular cutting edge section (7) and the radius of the annular clearance section (6) is not less than 0.3mm.
3. The method of machining a thin, tall, straight cylindrical electrode according to claim 1, characterized in that the length of the annular cutting edge section (7) is not more than 1mm; the difference between the outer diameter of the cutter bar section (8) and the outer diameter of the annular cutting edge section (7) is not smaller than 0.01mm.
4. Method for machining a thin, tall, straight cylindrical electrode according to claim 1, characterized in that in step B, a 3D model of the open-thick geometrical part (1) is built by programming software before the roughing is performed, the 3D model of the open-thick geometrical part (1) completely surrounding the electrode teeth (4).
5. The method for machining a thin, tall, straight cylindrical electrode according to claim 1, characterized in that in step B, rough machining selects cavity milling, milling the milled geometric part (1) is selected, and milling is selected, leaving a rough cut allowance for rough machining; the rotation speed of the clamping tool in the rough machining process is 5000-6000 rpm, the cutter feeding amount is 0.4-0.6 mm, the rough cutting allowance of 0.25-0.4 mm is reserved, and the feeding amount is 2500-3000 mm.
6. A method of machining a thin, tall, straight cylindrical electrode according to claim 1, characterized in that the draft angle a of the open-thick geometrical component (1) is in the range of 1.8 ° to 2.4 °.
7. The method of claim 1, wherein in step a, positioning and mounting the electrode blank on the machining site of the machine tool by a clamping tool comprises: the electrode blank is clamped and fixed on a workbench of a triaxial vertical machining center through a 3R clamping fixture, and the triaxial vertical machining center is used as a machine tool to machine the electrode blank in a triaxial machining mode; the electrode blank is a brass blank.
8. Method for machining a thin, high, straight cylindrical electrode according to claim 1, characterized in that in step C the part of the electrode teeth (4) is made smaller by a distance of the spark gap before finishing by means of the offset surface function of the programming software modeling module.
9. Method for machining a thin, tall, straight cylindrical electrode according to claim 1, characterized in that in step C finishing the open-thick geometrical part (1) by means of helical cutting comprises: selecting a curved surface area driving method, and adopting a spiral cutting mode to carry out forward milling on the electrode teeth (4); the rotating speed of the clamping tool is 5000-6000 rpm, the cutter feeding amount is 0.03-0.10 mm, and the feeding amount is 500-1100 mm.
10. The method for manufacturing a thin high straight cylindrical electrode according to claim 1, further comprising step D of detecting surface roughness, shape and concentricity of the electrode after finishing to determine whether it is acceptable or not; and (3) repeating the step A, the step B and the step C by adjusting the cutting parameters for unqualified electrodes until the machining is qualified.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202311168700.7A CN116900650A (en) | 2023-09-12 | 2023-09-12 | Processing method of thin and high straight cylindrical electrode |
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| Application Number | Priority Date | Filing Date | Title |
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| CN202311168700.7A CN116900650A (en) | 2023-09-12 | 2023-09-12 | Processing method of thin and high straight cylindrical electrode |
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|---|---|---|---|---|
| JP2009056533A (en) * | 2007-08-31 | 2009-03-19 | Hitachi Tool Engineering Ltd | Long neck radius endmill |
| US20110027025A1 (en) * | 2008-04-11 | 2011-02-03 | Mitsubishi Materials Corporation | Tool body of plunge cutting cutter, plunge cutting cutter, and plunge cutting method |
| JP2016097452A (en) * | 2014-11-18 | 2016-05-30 | 三菱マテリアル株式会社 | End mill |
| CN111958068A (en) * | 2020-06-30 | 2020-11-20 | 宝利根(成都)精密工业有限公司 | Thin and high electrode and processing method thereof |
| CN114247922A (en) * | 2022-01-26 | 2022-03-29 | 成都宝利根创科电子有限公司 | Processing method of array type needle point gate electrode |
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2023
- 2023-09-12 CN CN202311168700.7A patent/CN116900650A/en active Pending
Patent Citations (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2009056533A (en) * | 2007-08-31 | 2009-03-19 | Hitachi Tool Engineering Ltd | Long neck radius endmill |
| US20110027025A1 (en) * | 2008-04-11 | 2011-02-03 | Mitsubishi Materials Corporation | Tool body of plunge cutting cutter, plunge cutting cutter, and plunge cutting method |
| JP2016097452A (en) * | 2014-11-18 | 2016-05-30 | 三菱マテリアル株式会社 | End mill |
| CN111958068A (en) * | 2020-06-30 | 2020-11-20 | 宝利根(成都)精密工业有限公司 | Thin and high electrode and processing method thereof |
| CN114247922A (en) * | 2022-01-26 | 2022-03-29 | 成都宝利根创科电子有限公司 | Processing method of array type needle point gate electrode |
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