CN1269274A - 金属丝电极 - Google Patents

金属丝电极 Download PDF

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CN1269274A
CN1269274A CN00104820A CN00104820A CN1269274A CN 1269274 A CN1269274 A CN 1269274A CN 00104820 A CN00104820 A CN 00104820A CN 00104820 A CN00104820 A CN 00104820A CN 1269274 A CN1269274 A CN 1269274A
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B·巴特尔
B·诺伊泽尔
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    • C23C28/00—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
    • C23C28/02—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D only coatings only including layers of metallic material
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Abstract

一种火花磨蚀切割用金属丝电极;具有承受主要张力的导电芯丝,还有一个在磨蚀过程中磨耗的双层护套。这种金属丝电极的另一方面的结构使之既适合于对工件进行快速切割、又适合于精密切割。内层护套主要是用一种均质合金制成的,含有供快速切割用的组分;护套的外层含有适合于供精密切割用的组分,其中锌的分量高于80%,外层的厚度可达护套其余层厚的五分之一。

Description

金属丝电极
本发明涉及一种供火花磨蚀切割用的金属丝电极，有一个导电的、承受主要张力的芯丝，和一个至少由两层构成的护套。
一件工件能够用一个这样的金属丝电极进行磨蚀或切割。此时的切割几乎总是通过一次主切割(快速切割)和一次或多次后切割(精细切割)完成的。快速切割的任务是从整块材料上切下工件的轮廓。由于有待切割材料量的关系，这是最费时的切割工序。为了尽可能缩短工作时间，要采用很高的放电能量进行加工。为此，最好使用附有高含锌量外套的金属丝。在磨蚀过程中，护套本身的消耗量较小。与此同时，必须使磨蚀钢丝以很高的速度穿过切割缝隙，从而保证护套层不会在切割缝隙中完全用尽。虽然因此要用快速切割，但是这样的缺点是，经过切割或磨蚀的工件在许多用途中不够条件。高能放电在切割面上造成不平坦的表面。另外，由于电极的消耗，使切割缝隙成为锥体。这就需要一次或多次的后切割。
在后切割或精细切割过程中不过是对工件进行精加工。从而将表面磨光，并且将与轮廓不相符的部分磨掉。这只需要释放少量能量就能达到，从而使工件达到规定的质量(平行度、表面粗糙度、尺寸精度)。后切割的次数主要以工件要争取达到的质量为准。
为磨蚀工件在磨蚀电极和工件之间的放电是在消电离的空间进行的。为了能够通常在这样的消电离空间中在金属丝电极和工件之间产生飞弧，必须为此准备一个导电通道，以便起动固有脉冲。元素锌特别适合于做这样的结构。本身只要用很小的能源或电流，就能快速可靠地形成第一道电桥。这对精细切割来说是一个优点。出于这样的理由，使采用锌做包层的金属丝电极找到了宽阔的用途。这类的金属丝电极的芯材可以采用任何一种材料，优选的是铜、黄铜、钢和复合金属丝(钢-铜)。在连接小功率发电机的旧式WEDM-机上使用这种具有锌复层的电极，切割效果的升高明显高于无复层的电极。另一个优点特别是，由于锌很易蒸发，就能够在很小的电能下进行稳定的磨蚀工序。正如以上所述，这是磨蚀非常精细的表面的前提条件。
由于发电机的发展，如今已经能够做到产生富能的电火花。这样反而将锌的容易蒸发的优点转变成缺点，因为锌在作业过程中被迅速剥蚀，从而使其特别在快速切割中不能供磨蚀之用。为了对这样的剥蚀消耗进行平衡而提高锌层的厚度经证明是无效的。
为了对此进行补救，提供了黄铜复层的金属丝电极。在这种黄铜复层的金属丝电极中，用高含锌量的黄铜合金作为芯丝的护套。使用这项开发，用一种高含锌量的合金层取代了蒸发温度非常低、具有剥蚀消耗高的缺点的锌层。其优点是，外面护套层的抗磨蚀损耗性能高于纯锌层。高含锌量的黄铜层的层厚可以大大高于一层纯锌层。采用这种办法，使这种电极能够在连接大功率发电机的新式WEDM机上作为快速切割之用。然而与锌复层的电极相比还有一个缺点，就是磨蚀工件表面的质量没有象采用锌复层的电极磨出的表面质量那样高。即便使用带有经过扩散处理护套的金属丝进行多次后切割，也不能获得象采用Zn复层的电极所获得的那样表面质量。
作为本发明的依据的任务是：提供一种方法和一种金属丝电极，用来在工件上形成一种精细表面，也就是进行精密切割，另一方面能以采用快速切割法对工件进行高速切割。
此项任务按照权利要求1或13的特征得以完成。
按照本发明的金属丝电极既适合于快速切割，又适合于精密切割。进行快速切割时，在工件和金属丝电极之间有一股强电流流过。此时，护套外层直接被蚀掉，所以这层只有可以忽略不计的一部分在快速切割中起作用。在快速切割中，有阻抗能力的内层承受主负荷。结果产生精细切割的作用，流过的电流小，仅只消耗外层-也就是锌含量高的那层。这样就使按照本发明的金属丝电极成为万能电极，既适合于快速切割，又适合于精密切割，从而在工件的表面形成精密表面。由于使用本发明的电极既能进行快速切割、又能进行精细切割，所以在工作过程中就不需要更换电极。这样就省却了停车和装配的时间，也不必每次都要从新操作和调校工件。
用100％的锌制成护套的外层是有利的。含锌量为37至60重量％的内层是有利的。内层的锌存在于黄铜合金之中，其中的锌组份占40至48％。内层最好是具有均质的g-和/或r-结构。在具有这样的面心立方结晶格子的情况下，锌原子的化合方式使它能够从金属丝电极中释放出来，从而在工件和金属丝电极之间引弧；另一方面，结合紧密，所以消耗量有限。
另外的有利之处在于内层厚度为2.5μm，金属丝电极外层厚度在0.5至5μm是有利的。
金属丝电极最为有利的结构是：用CuZn合金20制成的芯丝的直径是0.25mm，内层的锌含量为45％，厚15-20μm，外层的层厚为2-3μm。金属丝电极的抗张强度至少为800N/mm2
第二种最为适合的结构的芯丝是用CuZn合金35制成的，内层的锌含量为45％，厚度为10-15μm，外层厚度为1-2μm。金属丝电极的第二种结构有利之处是抗张强度为900N/mm2。按照本发明的金属丝电极，不论是第一种结构还是第二种结构，都能够具有12-50MS/m的导电率。
按照本发明制造上述金属丝电极时要划分成几步进行：
在第一步之中，在芯丝上包覆一层内层。有利的方法可以是采用金属包覆法、电镀法、粉末涂层法或者火焰喷涂金属法。然后，有时候在第二步中将金属丝电极进行扩散退火。接着在下一步中在内层上包覆外层。最后，采用这样的办法将金属丝电极的直径加工成预定的尺寸，就是在不对金属丝电极进行加热的条件下使护套的组成和结构保持不变；否则会产生严重的扩散。
扩散退火可以采用穿过一台流化床加热炉的有利的办法，经过从350℃至600℃的升温和2分钟的退火时间完成。
在扩散退火之后，经过迅速冷却，使其在扩散状态下定型。
以下对于两个有利的实施例进行详细叙述：
在按照本发明的第一个实施例中，金属丝电极的直径是0.25mm，外层的层厚为2-3μm，内层的层厚为15-20μm。外层是一层纯锌层，内层是一层黄铜层，锌组分的份额为45％。这种金属丝电极的钢丝的抗张强度约为800N/mm2电导率为17MS/m。
在按照本发明的第二个实施例中，金属丝电极的直径仍然是0.25mm，外层的层厚为1-3μm，内层的层厚为10-15μm。外层还是一层纯锌层，内层仍然象在第一个实施例中那样是一层黄铜层，锌组分的份额为45％。这种金属丝电极的钢丝的抗张强度约为900N/mm2电导率为15MS/m。

Claims (16)

1·火花磨蚀切割用金属丝电极，具有一个导电的并且主要承受张力的芯丝，并且具有双层护套，其在磨蚀过程中磨耗，其特征在于：内层护套主要是用一种均质合金制成的，含有供快速切割用的组分；护套的外层含有适合于供精密切割用的组分，其中锌的分量高于80％，外层的厚度可达护套其余层厚的五分之一。
2·如权利要求1中的金属丝电极，其特征在于：外层是由100％的锌制成的。
3·如权利要求1或2中的金属丝电极，其特征在于：内层含锌量为37至60重量％。
4·如权利要求1至3中的金属丝电极，其特征在于：内层是用黄铜制成的，其中的锌组分占40至48重量％。
5·如权利要求1至4中的金属丝电极，其特征在于：内层具有均质的B-和/或r-结构。
6·如权利要求1至5中的任一种金属丝电极，其特征在于：内层厚度至少为2.5μm。
7·如权利要求1至6中的任一种金属丝电极，其特征在于：外层厚度在0.5至5μm。
8·如权利要求1至7中的任一种金属丝电极，其持征在于：芯丝是由CuZn 20构成，内层含有45重量％的锌组分，层厚为15-20μm；外层厚度为2至3μm。
9·如权利要求8中的金属丝电极，其特征在于：金属丝电极具有至少800N/mm2的抗张强度。
10·如权利要求1至7中的任一种金属丝电极，其特征在于：芯丝是用一种CuZn合金制成的，其中含有35-37重量％的Zn；内层含锌的份额为45重量％，并且层厚为10-15μm，外层层厚为1-2μm。
11·如权利要求10中的金属丝电极，其特征在于：金属丝电极具有至少900N/mm2的抗张强度。
12·如权利要求8至11中的任一种金属丝电极，其特征在于：金属丝电极具有特殊的电导率12至50MS/m。
13·制造如权利要求1至12之一的电极的方法，该电极具有芯丝和由一层内层和一层外层构成的护套，其特征在于：
a)第一步，优选采用金属包覆法、电镀法、粉末涂层法、火焰喷涂金属法，在金属丝电极的芯丝上包覆一层内层，
b)可能在第二步将金属丝电极进行扩散退火，
c)在下一步中，在内层上包覆外层，
d)最后，采用这样的办法将金属丝电极的直径加工成预定的尺寸，就是将金属丝电极在加热的条件下使护套的组成基本保持不变，以不产生严重的扩散。
14·如权利要求13中的制造方法，其特征在于：通过传送，穿过一台流化床加热炉，经过从350℃至600℃的升温和2分钟的退火时间，进行扩散退火。
15·如权利要求13至14中的任一种方法，其特征在于：在扩散退火之后，经过迅速冷却，完成保持既得结构的定型。
16·如权利要求15中的方法，其特征在于：内层的结构是一种由a+B或者仅只B或r或者B+r的结构构成的。
CN00104820A 1999-03-25 2000-03-27 金属丝电极及其制造方法 Expired - Fee Related CN1121291C (zh)

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Cited By (4)

* Cited by examiner, † Cited by third party
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CN105102180A (zh) * 2012-09-17 2015-11-25 复合概念公司 用于电火花加工的金属丝电极
CN105312690A (zh) * 2014-06-10 2016-02-10 严雅扬 一种放电加工切割线及其制造方法
WO2016023326A1 (zh) * 2014-08-13 2016-02-18 宁波博威麦特莱科技有限公司 一种高精度锌基合金电极丝及其制备方法
CN113823435A (zh) * 2021-09-08 2021-12-21 湖州金钛导体技术有限公司 一种复合电极丝、复合电极丝的制备方法及应用

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CN105312690A (zh) * 2014-06-10 2016-02-10 严雅扬 一种放电加工切割线及其制造方法
CN105312690B (zh) * 2014-06-10 2018-08-10 严雅扬 一种放电加工切割线及其制造方法
WO2016023326A1 (zh) * 2014-08-13 2016-02-18 宁波博威麦特莱科技有限公司 一种高精度锌基合金电极丝及其制备方法
CN113823435A (zh) * 2021-09-08 2021-12-21 湖州金钛导体技术有限公司 一种复合电极丝、复合电极丝的制备方法及应用
CN113823435B (zh) * 2021-09-08 2024-04-23 湖州金钛导体技术有限公司 一种复合电极丝、复合电极丝的制备方法及应用

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BR0001417B1 (pt) 2011-03-22
DE50014229D1 (de) 2007-05-24
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TW469199B (en) 2001-12-21
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CA2300675A1 (en) 2000-09-25
EP1038625A3 (de) 2004-01-21
RU2199423C2 (ru) 2003-02-27
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DE19913694A1 (de) 2000-11-02
KR100376755B1 (ko) 2003-03-19
JP2005097728A (ja) 2005-04-14
ATE359144T1 (de) 2007-05-15
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