EP3924129A1 - Fil-électrode pour découpage par électro-érosion et procédé pour la fabrication dudit fil-électrode - Google Patents

Fil-électrode pour découpage par électro-érosion et procédé pour la fabrication dudit fil-électrode

Info

Publication number
EP3924129A1
EP3924129A1 EP20723174.7A EP20723174A EP3924129A1 EP 3924129 A1 EP3924129 A1 EP 3924129A1 EP 20723174 A EP20723174 A EP 20723174A EP 3924129 A1 EP3924129 A1 EP 3924129A1
Authority
EP
European Patent Office
Prior art keywords
wire
particles
block
wire electrode
zinc
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
EP20723174.7A
Other languages
German (de)
English (en)
Inventor
Stefan Rink
Bernd Barthel
Tobias Nöthe
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Berkenhoff and Co KG
Original Assignee
Berkenhoff and Co KG
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Berkenhoff and Co KG filed Critical Berkenhoff and Co KG
Publication of EP3924129A1 publication Critical patent/EP3924129A1/fr
Pending legal-status Critical Current

Links

Classifications

    • 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
    • B23H7/08—Wire electrodes
    • 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
    • B23H7/22—Electrodes specially adapted therefor or their manufacture
    • B23H7/24—Electrode material
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C9/00—Alloys based on copper
    • C22C9/04—Alloys based on copper with zinc as the next major constituent
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22F—CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
    • C22F1/00—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
    • C22F1/08—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of copper or alloys based thereon

Definitions

  • the present invention relates to a wire electrode for spark erosion cutting and a method for its manufacture.
  • Spark erosion processes are used to separate electrically conductive workpieces and are based on the removal of material with the help of spark discharges between the workpiece and a tool.
  • controlled spark discharges are brought about by applying voltage pulses between the workpiece in question and the tool which is arranged at a short distance from it and which functions as an electrode in a dielectric liquid such as deionized water or oil.
  • workpieces which for example consist of metals, electrically conductive ceramics or composite materials, etc., can be processed essentially independently of their hardness.
  • the electrical energy for the spark discharges is provided by the pulse generator of the eroding machine.
  • a special spark erosion process in which the tool is formed by a ge tensioned, thin wire with typical diameters in a range of approximately 0.02 to 0.4 mm, is spark erosion cutting or wire erosion. Since the wire wears out during the erosion process due to material removal, it has to be constantly pulled through the cutting or processing zone and can only be used once, i.e. the wire is consumed continuously.
  • the desired cutting contour is first carried out by a so-called main cut with a relatively high discharge energy. In order to improve the contour accuracy and the surface roughness of the workpiece, the main cut can be followed by one or more so-called recuts with successively reduced discharge energy. With these recuts, the wire electrode is only in contact with part of its circumference.
  • coated wire electrodes In practice, both coated and uncoated wires or wire electrodes are used, which today are mostly made on a brass or copper basis.
  • Uncoated wire electrodes also known as bare wires, consist of a homogeneous material, while coated wire electrodes electrodes have a sheathed or coated core.
  • coated wire electrodes are usually constructed in such a way that a sheathing, which can be made up of a sheath layer or several superimposed layers, is responsible for the actual erosion process, while the core of the wire electrode for example, the tensile strength required for the wire passage and the wire prestressing and the necessary electrical and thermal conductivity.
  • Bare wires are typically made of brass with a zinc content of between 35 and 40% by weight, while most coated wires have a core made of copper or brass and one or more sheath layers made of zinc or a copper-zinc alloy.
  • zinc and brass due to the presence of zinc with its low evaporation temperature, offer the advantages of a relatively high removal rate and efficiency of the erosion process and the possibility of transferring very small pulse energies for fine finishing of workpiece surfaces, i.e. machining with the lowest possible surface roughness.
  • wire electrodes are often used for the purpose of fine finishing, which have a coating layer that consists predominantly or exclusively of zinc.
  • the removal rate or cutting performance can be increased by using wires which are provided with a coating of pure or predominantly pure zinc. It is also known that a thin cover layer, e.g. made of zinc oxide or cadmium oxide is advantageous for the cutting performance of a wire electrode (see. US 4,977,303). It is also known that wires with a coating of ⁇ or ⁇ 'phase brass in turn achieve a higher cutting performance than the aforementioned galvanized wires, since the zinc bound in the ⁇ or ⁇ ' brass alloy is in comparison evaporates more slowly to form pure zinc and is therefore available for a sufficiently long time to promote removal while the wire passes the cutting or processing zone.
  • the zinc content of the jacket can be increased further, and compared to the aforementioned wires with ß- or ß'- Brass coating in principle the same or higher cutting performance can be achieved.
  • sheaths have also been proposed individually, partly inevitably due to diffusion processes taking place during the corresponding manufacturing process, which have a brass sheath layer with a phase mixture, for example of a- and ß-phase or of ß- and g-phase.
  • US Pat. No. 7,723,635 proposes a wire electrode which has a core and a first cladding layer made of a brass alloy with approx. 37-49.5% by weight zinc, with evenly distributed so-called grains embedded in the cladding layer which are spaced apart and which contain a brass alloy with a zinc content of approx. 49.5 - 58% by weight zinc.
  • the erosion properties should be increased due to improved electrical conductivity and strength.
  • At least one of several cladding layers has predominantly a fine-grained mixture of ⁇ and g brass.
  • the g-brass By integrating the g-brass in a matrix made of ß-brass, the g-brass should not wear out too quickly during the erosion process, but rather be released into the erosion gap in small doses with effective removal.
  • EP-A-1 846 189 a wire electrode is proposed which contains a first layer of ⁇ -brass and a torn layer of g-brass, in the gaps of which the layer of ⁇ -brass appears.
  • EP-A-2 517 817 describes a wire electrode with two alloy layers formed by diffusion.
  • the core wire material appears along cracks sen in the second alloy layer, so that a plurality of grain-like structures are formed on the surface.
  • KR-A-10-2007-0075516 discloses, inter alia, a method for producing a wire electrode with a predetermined thickness of the diffusion layer.
  • a core wire made of copper, a copper alloy or a copper-clad steel wire by hot-dip dipping, the aim is to prevent the wire from stretching and thus the thickness of the diffusion layer being created cannot be controlled.
  • a core wire made of copper, a copper alloy or steel is coated with a first metal, which has a lower evaporation temperature than copper.
  • a dimension between 2 and 4 mm is preferably chosen instead of a dimension of the core wire of, for example, 0.90 mm.
  • the coated core wire is heat-treated in order to produce an alloy layer due to diffusion.
  • the heat treatment for producing the diffusion layer can alternatively take place in the course of the coating.
  • the wire is drawn.
  • the wire is heat-treated again in order to continue diffusion and bring about recrystallization.
  • the wire is coated with a second metal, which has a lower evaporation temperature than copper.
  • the wire coated with the second metal is drawn and in a seventh step the wire is heat-treated to stabilize it.
  • the object of the invention is to increase the economic efficiency of wire EDM technology by further increasing cutting performance and resistance to eroding.
  • Another object of the invention is not to worsen or even improve the contour accuracy and the surface quality of the electrical discharge machined workpiece compared to bare brass wires despite an increased cutting performance.
  • a further object of the invention is to provide a coating that is as abrasion-resistant as possible, so that the eroding processes operated with the wire electrode according to the invention do not experience any disturbances or impairments due to deposits of wire abrasion.
  • a wire electrode with the features of patent claim 1 is used to achieve this object.
  • the method with the features of patent claim 23 is used to produce the wire electrode according to the invention.
  • Advantageous embodiments of the wire electrode are the subject of the respective subclaims.
  • Figure 1 shows schematically and not true to scale a cross section (perpendicular to the longitudinal axis) of a first embodiment of the wire electrode according to the invention.
  • FIG. 2 shows a detailed section of the cross section of the first embodiment of the wire electrode 1 according to the invention according to FIG.
  • Figure 3 shows a detailed section of a cross section (perpendicular to the longitudinal axis) of a second embodiment of the wire electrode according to the invention.
  • FIG. 4 shows a detailed section of a cross section (perpendicular to the longitudinal axis) of a third embodiment of the wire electrode according to the invention.
  • FIG. 5 shows a scanning electron microscope (SEM) image of the surface of the first embodiment of the wire electrode according to the invention.
  • FIG. 6 shows a detailed section of a cross section (perpendicular to the longitudinal axis) of a fourth embodiment of the wire electrode according to the invention.
  • FIG. 7 shows an SEM image (backscattered electrons 20 kV) of a section of the outer circumference of a wire electrode according to the invention in a cross section perpendicular to the longitudinal axis of the wire.
  • FIG. 8 shows an SEM image (backscattered electrons, 20 kV) of the surface of a further embodiment of the wire electrode according to the invention, magnified 300 times.
  • FIG. 9 shows an SEM image (backscattered electrons, 5 kV) of the surface of a further embodiment of the wire electrode according to the invention, magnified 1000 times.
  • a wire electrode for electrical discharge cutting has a core which has a metal or a metal alloy. It is preferred that the core consists of more than 50% by weight and more preferably completely or essentially completely of one or more metals and / or one or more metal alloys. In particular, the core can accordingly be formed entirely from a metal or from a metal alloy.
  • the core can be made homogeneous or, for example, in the form of several metal or metal alloy individual layers of different composition arranged one above the other, vary in the radial direction. de have properties.
  • Essentially as used herein means that the wire according to the invention or a layer thereof or its core consists of the composition disclosed in each case and / or has the disclosed properties, manufacturing and measurement tolerances having to be taken into account, eg presence unavoidable impurities familiar to those skilled in the art.
  • the metal is in particular copper and the metal alloy is in particular a copper-zinc alloy.
  • cladding Surrounding the core is provided, for example in the form of a coating, a cladding (hereinafter also referred to as “cladding” for short), which comprises one or more cladding layers.
  • the jacket wears out during a wire eroding process and is intended to influence the eroding properties.
  • these are arranged one above the other in the radial direction, and each preferably runs around the core.
  • One of the cladding layers of the wire electrode according to the invention comprises areas which have a particle-like appearance (morphology), which is characterized in particular by an irregular contour which (viewed in a wire cross-section perpendicular or parallel to the wire's longitudinal axis) partially sharp corners with a corner radius of less than 2 pm and lines with a straightness which deviate less than 2 pm from an ideal straight line. These areas are therefore referred to as areas whose morphology corresponds to block-like or block-shaped particles. These areas are also referred to below as “areas with block-like morphology” or “block-like particles” (or “block-shaped particles”) for short.
  • the material of adjacent layers and / or the adjacent or radially further inward core material can protrude between the block-like particles.
  • the block-like particles are also spatially separated from one another by cracks over at least part of their circumference, from the material of the layer which comprises these areas, the material of adjacent layers and / or the core material.
  • the block-like particles themselves can have cracks.
  • the cracks generally have a width of up to about 2 ⁇ m, predominantly about 1 ⁇ m, as can be determined by means of scanning electron microscopy under normal conditions, for example by analyzing an image measured on the basis of backscattered electrons (20 kV). If a larger crack width is found along the course of a crack over a short distance (for example 1 to 2 ⁇ m), this structure is also regarded as a crack in the sense of the present invention. In comparison, they will be wider Distances between the block-like particles (which usually form radially inward from the outer surface of the wire) are referred to as depressions or gaps.
  • zinc oxide can form along the cracks, but also along the depressions and gaps, which can reduce the width of the cracks or partially fill their volume.
  • this can also be reproduced by means of suitable scanning electron microscopy recording techniques, so that in this case too the morphology of the block-shaped particles determined by the crack formation can be recognized.
  • the predominant, i.e. the part of the area of the block-like particles amounting to more than 50% has a copper-zinc alloy with a zinc concentration of 38-49% by weight.
  • the alloy in this part of the surface is partially or predominantly in the form of ⁇ and / or ⁇ 'phase.
  • the part of the area of the block-like particles amounting to less than 50% has a copper (zinc) alloy with a zinc concentration of more than 49-68% by weight.
  • the alloy is present in this part of the surface as a b + g phase and / or as a g phase.
  • the area used to determine the composition of the particle is defined by considering the shortest straight line connecting the ends of the cracks that separates the particle from the surroundings ( partially), choosing the ends that are closest to the center of the wire in the radial direction (that is, the furthest inside). This is shown by way of example in FIGS. 6 and 7, to which reference is made here within the scope of this definition.
  • a particle is separated from its surroundings not only by cracks but (also) by a depression (gap)
  • the connecting line between the end of the crack and the radially most inner point of the depression (gap) closest to the end of the crack is selected. This is also shown by way of example in FIG. 7, to which reference is made here within the scope of this definition.
  • the block-like particles according to the invention are viewed in a wire cross-section perpendicular or parallel to the longitudinal axis of the wire.
  • tet (as defined above) completely separated by cracks from the environment, ie from one another, from the material of the layer which comprises these particles, the material of one or more layers and / or the core material.
  • the ß'-phase is stable below a certain temperature and has an ordered grid with defined grid locations for the copper and zinc and, when this temperature is exceeded, into the disordered ß-phase passes over, in which the atoms are distributed stati stically on the lattice sites of a body-centered cubic lattice. Since the conversion between ß-phase and ß'-phase cannot be suppressed according to the prevailing opinion and also has only minor effects in terms of its mechanical and electrical properties, in the context of this application with a general reference to the ß-phase, the ß 'Phase meant unless a distinction is expressly made.
  • block-like particles can have a plurality of grains in the metallurgical sense.
  • the block-like particles can spatially separate them along the cracks and crevices that separate them over part of their circumference from the material of the layer that comprises these particles, the material of adjacent layers and / or the (adjacent) core material, as well as along the cracks having the block-like particles themselves include zinc oxide.
  • the copper-zinc alloys which have the block-like particles, can, in addition to copper and zinc, one or more metals from the group of Mg, Al, Si, Mn, Fe, Sn with a total proportion of 0.01 to 1 wt .-% , exhibit.
  • the thickness of the block-like particles measured in the radial direction of a wire cross section is preferably 1 to 30 ⁇ m.
  • the wire electrode can also have a thin cover layer, which consists predominantly of Zn, a Zn alloy, or ZnO in a thickness of, for example, about 0.05-1 ⁇ m.
  • a thin cover layer can also be located on the blocky particles, which predominantly, ie more than 50% by weight, has zinc oxide in a thickness of, for example, about 0.05-2 ⁇ m.
  • This top layer has areas ("gaps") in which the material of the block-like particles, that is, one of the copper-zinc alloys that have the block-like particles appears.
  • these areas have a lamellar structure such that alternating lamellas, formed from the cover layer, which predominantly comprises zinc oxide, and formed from the material of the block-like particles, are arranged one after the other.
  • Such areas are shown in FIGS. 8 and 9 by way of example.
  • Lamellae are usually understood to mean structures which are characterized by platelets or thin layers, which are located in a structure similarly on ordered parallel or radial structural elements of this type (platelets / thin layers).
  • the lamellar structural areas are not arranged strictly parallel and the distance between the individual lamellae can vary. Nonetheless, it is clear to those skilled in the art what is meant by lamellar. In this respect, a comparison with the known flake graphite can be drawn.
  • Flake graphite describes the most common type of cast iron in which graphite is present in the form of thin, irregularly shaped lamellae.
  • the lamellar structural elements which appear as whitish, lighter areas in FIGS. 8 and 9, consist of the material of the block-like particles.
  • the lamellar areas which appear as grayish, darker areas, consist of the top layer of (predominantly) zinc oxide.
  • lamellae The dimensions of the lamellar structures (hereinafter also referred to as “lamellae” for short) are as follows.
  • the width of the lamellae, which are formed from the material of the block-like particles, is less than 5 ⁇ m, preferably less than 3 ⁇ m and even more preferably less than 2 ⁇ m.
  • the length of the lamellae can be up to 50 pm.
  • the width of the slats can vary over the length of the slats.
  • the lamellae which are formed from the material of the block-like particles, can in part be connected to one another by narrow webs, so that a network-like structure is formed on the wire surface from the material of the block-like particles.
  • a unit area of 50 ⁇ 50 gm 2 in an SEM image (backscattered electrons, 20 kV) when the wire is viewed from above along its longitudinal axis (ie in a view as shown in FIGS. 8 and 9) the lamellae, which consist of the material of the block-like particles are formed, make up a proportion of up to 50%.
  • the metals contained in the core and the coating can contain unavoidable impurities.
  • the cracks that spatially separate the block-like particles from one another, at least over part of their circumference, from the material of the layer containing these particles, the material of adjacent layers and / or the (adjacent) core material, and the cracks that separate the block-like particles can have themselves, favoring increases in the electric field and thus the ignition of the electrode. Due to the high level of spark erosion wear resistance due to the zinc content of 38-49% by weight in their predominant part, the block-like particles can contribute to a higher ignitability for a longer period. This effect is particularly noticeable in the first 2 recuts when using the wire electrode according to the invention, since the block-like particles are effective for longer because of the successively reduced discharge energy compared to the main cut.
  • the increased surface area due to the fissured layer also generally improves the cooling of the wire electrode.
  • the cutting performance is increased by the top layer of zinc oxide, which has gaps in which the material of the block-like particles appears.
  • a lamellar surface structure as defined above in which alternating lamellas, formed from the cover layer, which predominantly comprises zinc oxide, and formed from the material of the block-like particles, are arranged side by side, has an advantageous effect on the cutting performance.
  • the thickness of the block-like particles is advantageously in a range of 1 - 30 gm. With thicker particles, there is a risk of whole particles loosening due to insufficient connection to the adjacent wire core or the adjacent cladding layer. This can lead to short circuits and thus to impairment of the contour accuracy and surface quality of the eroded component. If the thickness is less than 1 gm, the positive effects of ignitability and cooling effect are no longer sufficient.
  • the thickness of the block-like particles, measured in the radial direction of a wire cross section is more preferably 2-15 ⁇ m and even more preferably 3-10 ⁇ m.
  • the cladding layer can be applied to the core, for example, by suitable coating processes, possibly in combination with a heat treatment process.
  • the coating layer can be applied physically or electrochemically, for example, and steps to reduce the wire diameter can also follow, if necessary.
  • a starting material in the form of a wire made of Cu, CuZn 2 o or CuZn 37 (brass with 20 or 37 wt.% Zinc) with a diameter of, for example, 1.20 mm can be assumed, which, for example, galvanically or by hot dipping, is coated with Zn.
  • the wire coated with Zn is then subjected to a diffusion annealing in which a cladding layer is produced which has an at least partially and in particular continuous and homogeneous partial layer made of g-brass.
  • the zinc content in this part of the jacket layer is accordingly 58-68% by weight.
  • the wire is tapered to an intermediate dimension or the final dimension, preferably by cold forming.
  • the block-like particles are spatially separated from one another, so that the material of adjacent layers and / or the (adjacent) core material can appear between the block-like particles.
  • the block-like particles themselves can have cracks.
  • the wire is then subjected to a further diffusion annealing so that the predominant part, ie the part of the block-like particles amounting to more than 50%, has a zinc content of 38-49% by weight.
  • the composition is determined in relation to a wire cross-section, viewed perpendicularly or parallel to the wire axis. The considered particle area is defined as above.
  • the part of the block-like particles with the composition according to the invention is preferably in the region of the block-like particles facing radially towards the core.
  • the part of the block-like particles amounting to less than 50% has a copper alloy with a zinc concentration of more than 49-68% by weight.
  • the diffusion of the zinc from the block-like particles into the neighboring material forms a diffusion layer with a zinc content of 38-58% by weight.
  • the size of the part of the block-like particles which has a zinc content of 38-49% by weight can be determined via the intensity, i. the temperature and duration of the annealing can be influenced.
  • Both diffusion annealing can be carried out stationary, for example in a bell-type furnace, or in a continuous process, for example by resistance heating.
  • the first diffusion annealing can be carried out, for example, in a hood furnace under an ambient atmosphere or protective gas, preferably in a range of 180-300 ° C for 4-12 h, the mean heating rate preferably at least 80 ° C / h and the mean cooling rate preferably at least 60 ° C / h. It can alternatively take place, for example, by resistance heating in the run under ambient atmosphere or protective gas, the average heating rate preferably being at least 10 ° C / s, the max.
  • Wire temperature is preferably between 600 and 800 ° C
  • the annealing time is preferably in the range of 10-200 s and the mean cooling rate is preferably at least 10 ° C / s.
  • the above glow times relate to the period from leaving room temperature until reaching room temperature again.
  • the second diffusion annealing can be carried out, for example, in a hood furnace under ambient atmosphere or protective gas, preferably in a range of 300-520 ° C for 4-24 h, the mean heating rate preferably at least 100 ° C / h and the mean cooling rate preferably at least 80 ° C / h is.
  • Wire temperature is preferably between 350 and 600 ° C
  • the annealing time is preferably in the range of 10-200 s and the mean cooling rate is at least 10 ° C / s.
  • the above glow times refer to the period from leaving room temperature until room temperature is reached again.
  • one or more further coating steps with zinc and / or one or more further diffusion annealing processes can follow before the wire is drawn into its final dimensions. It is possible that the wire is drawn before, during or after one of the above cooling processes. The wire is preferably converted into the desired final dimension by cold drawing. This can cause further cracks in the block-like particles and the surrounding jacket layer.
  • the formation of a lamellar or network-like surface structure can be achieved in which alternating lamellae are formed from the top layer, which predominantly comprises zinc oxide and ge forms from the material of the block-like particles, arranged side by side.
  • the formation of such a surface structure is favored by a total cross-section reduction of 60 to 85%.
  • the formation of such a surface structure is promoted by a cross-section reduction of 8 to 12% per drawing stage.
  • the cold drawing can optionally be followed by a so-called stress-relieving heat treatment in order to positively influence the straightness, tensile strength and elongation of the wire.
  • the stress relief annealing can e.g. by resistance heating, inductive or by thermal radiation.
  • At least one cladding layer is formed which comprises the block-like particles according to the invention which are spatially separated from one another, from the material of adjacent cladding layers and / or the (adjacent) core material, at least over part of their circumference.
  • the predominant part of the area (as defined above) of the block-like particles that is to say more than about 50%, has a copper-zinc alloy with a zinc concentration of preferably 38 - 49% by weight and more preferably 40-48% by weight %, with this part of the area in particular in the area of the block-like particles facing radially towards the core.
  • the portion of this area is preferably more than about 60%, more preferably more than about 80% and even more preferably about 100%.
  • At least a subset of the block-like particles (viewed in a wire cross-section as defined herein) is completely separated from one another by cracks, from the material of the layer that comprises these particles, the material of one or more further layers and / or the core material spatially separated.
  • the copper-zinc alloys which have the block-like particles contain, in addition to Cu and Zn, preferably one or more metals from the group of Mg, Al, Si, Mn, Fe, Sn with a total proportion of 0.01 to 1 wt. % on. More preferably, the copper-zinc alloys which have the block-like particles consist only of copper and zinc and also unavoidable impurities.
  • the outer cladding layer comprises the block-like particles which are spatially separated from one another, from the material of the adjacent cladding layer and / or the (adjacent) core material, at least over part of their circumference.
  • the predominant part of this embodiment ie the part of the area (as defined above) amounting to more than 50% of the block-like particles, has a copper-zinc alloy with a zinc concentration of 38 - 49 wt .-%, this part of the surface in particular in the area of the block-like particles facing radially towards the core.
  • the alloy in this part of the surface is partially or predominantly in the form of ⁇ and / or ⁇ 'phase.
  • the part of the area of the block-like particles, which is less than 50%, has a copper-zinc alloy with a zinc concentration of more than 49-68% by weight.
  • the alloy is present in this part of the area as a b + g phase and / or as a g phase.
  • the adjacent, inner jacket layer has a copper alloy with a zinc content of preferably 38-58% by weight.
  • the alloy in this part is partly or predominantly as a ß-phase or as a b + g-phase.
  • the inner jacket layer has a copper-zinc alloy with a zinc content of 38-51% by weight.
  • the topography of the adjacent layer differs from the outer mantle layer, in that its border lines to the outer mantle Layer and towards the core or a further cladding layer located underneath have an approximately wavy shape.
  • the adjoining, inner jacket layer is preferably continuous. However, it can also have interruptions in which the core material or another cladding layer underneath protrudes.
  • the jacket can have, for example, an outer jacket layer, preferably in the form of a cover layer, which forms part of the outer surface or the entire outer surface of the jacket layer, at least 50% by weight and preferably completely or essentially completely of zinc a zinc alloy or zinc oxide is formed.
  • the thickness of this top layer can be 0.05 - 1 pm.
  • the above lamellar or network-like structure Compared to a covering layer made of zinc oxide that is continuous over larger sections, the above lamellar or network-like structure has proven to be particularly suitable for increasing the cutting performance.
  • formed surface is through the second diffusion annealing, eg under ambient atmosphere, preferably a thin layer of zinc oxide.
  • a thin layer of zinc oxide is available for the eroding process to increase the removal rate.
  • the core is predominantly and preferably completely or essentially completely made of copper or a copper-zinc alloy with a zinc content of 2 to 40% by weight.
  • Such cores are advantageously cold-deformable se se.
  • the structure and the composition of the wire electrode according to the invention can, for example, be based on a scanning electron microscopic examination (SEM) Determine with energy dispersive X-ray spectroscopy (EDX).
  • SEM scanning electron microscopic examination
  • EDX energy dispersive X-ray spectroscopy
  • the production of a wire cross-section can, for example, be followed by the so-called ion slope cutting method, in which the wire is covered by a screen and irradiated with Ar + ions, with parts of the wire protruding from the screen being worn by the ions.
  • samples can be prepared free of mechanical deformations.
  • the structure of the jacket layer of the wire electrode according to the invention is therefore retained by such a preparation.
  • the structure of the cladding layer of the wire electrode according to the invention can thus be represented by the SEM images.
  • the composition of the wire electrode according to the invention can be determined on the basis of point-line and area-type EDX analyzes.
  • the wire electrode 1 shown in cross section in FIG. 1 has a wire core 2 which is completely surrounded by a jacket 3, 4 forming the outside of the wire electrode 1.
  • the core 2 is homogeneously completely or essentially completely made of copper or a copper-zinc alloy with a zinc content of preferably 2 to 40% by weight.
  • the outer cladding layer 3, 4 comprises block-like particles which are spatially separated from one another or from the material 4 (e.g. by cracks (not shown)).
  • the predominant part of the block-like particles in terms of area has a copper alloy with a zinc concentration of 38-49% by weight. According to the phase diagram for the CuZn system, the alloy in this part is partially or predominantly in the form of ⁇ and / or ⁇ 'phase.
  • the adjacent, inner cladding layer area 4 consists of a copper alloy which has a zinc content of 38-51% by weight. According to the phase diagram for the CuZn system, the alloy in this part is partially or predominantly in the form of a ⁇ phase.
  • This adjoining layer region can have a boundary line to the core or to a further cladding layer (not shown) which has an approximately wave-like shape. In this embodiment, the adjoining inner cladding layer area is formed continuously over the circumference.
  • FIG. 2 shows a detailed section of the cross section of the first embodiment of the wire electrode 1 according to the invention according to FIG. 1 with the wire core 2 and the outer cladding layer 3, 4.
  • Figure 3 shows a detailed section of the cross section of a second Ausense approximate form of the wire electrode according to the invention with the wire core 2 and the outer sheath layer 3, 4.
  • the inner sheath layer area 4 is interrupted at several points, whereby the core wire protrudes from these points on the surface of the wire electrode.
  • FIG. 4 shows a detailed section of the cross section of a third embodiment of the wire electrode according to the invention with the wire core 2 and the outer cladding layer 3, 4, 5.
  • the predominant part of the area of the block-like particles consists of a copper-zinc alloy with a zinc concentration of 38 49% by weight, this part in this embodiment being in the area of the block-like particles facing radially towards the core.
  • the alloy in this part is partially or predominantly in the form of ⁇ and / or ⁇ 'phase.
  • the outer region 5 of the block-like particles has a zinc content of more than 49-68% by weight.
  • the alloy is present in this part as a b + g phase and / or as a g phase.
  • FIG. 5 shows a scanning electron microscope image of the surface of the first embodiment of the wire electrode according to the invention.
  • the block-like particles of the outer jacket layer as well as cracks and depressions (gaps) can be seen.
  • All of the embodiments shown in FIGS. 1 to 5 can have a thin cover layer on the blocky particles (see FIG. 6), which forms part or the entire outer surface of the jacket layer 6.
  • This layer is formed to an extent of at least or more than 50% by weight of zinc, a zinc alloy and zinc oxide or consists of zinc oxide.
  • the thickness of this cover layer is up to 0.05-1 ⁇ m or up to 2 ⁇ m.
  • the cover layer can have gaps in which the material of the block-like particles appears.
  • the block-like particles can move along the cracks and crevices that are covered by the material at least over part of their circumference spatially separate neighboring layers and / or the neighboring core material (7), as well as zinc oxide along the cracks that the block-like particles themselves have (7 ').
  • a block-like particle in a cross-section parallel or transversely to the longitudinal axis of the wire is not completely delimited by cracks from the material of neighboring layers or the core material based on a scanning electron microscopic analysis
  • the definition of the area of the block-like particle should be that it extends through the shortest straight connection between the end points (a, b) of the surrounding cracks (7), which are located closest to the wire center point in the radial direction (see FIG. 6).
  • FIG. 7 is an SEM image (backscattered electrons 20 kV) of a section of the outer circumference of a wire electrode according to the invention in a cross section perpendicular to the longitudinal axis of the wire.
  • Block-shaped particles can be seen which are separated from one another by cracks at least over part of their circumference.
  • the straight connecting lines a - b and a ‘- b‘ illustrate how in these cases the area of the particles is determined, more than 50% of which is a copper alloy with a zinc concentration of 38 to 49% by weight.
  • the area is determined by the fact that the shortest straight connection line between the ends of the cracks located furthest inward in the radial direction towards the center of the wire, which separate the particle from the surroundings, is selected as the boundary becomes.
  • this is the connecting line a - b, in accordance with the determination method already explained with reference to FIG.
  • the straight connection from one crack end to the “neighboring” (closest) crack end is selected.
  • the particle on the right in the image is separated from its surroundings by a depression to the right.
  • the connecting line between the cracks and the radially most inner point of the closest recess (gap) is chosen.
  • FIG. 8 and FIG. 9 show an SEM image (backscattered electrons, 20 kV and 5 kV, respectively) of the surface of a further embodiment of the wire electrode according to the invention in 300-fold and 1000-fold magnification.
  • Areas with a lamellar structure (8) can be recognized on the basis of the color contrasts.
  • the lamellae appear from the Cover layer, which has predominantly zinc oxide, are formed as gray, darker areas.
  • the black areas represent cracks and depressions.
  • Second diffusion annealing in a bell-type furnace under ambient atmosphere at 400 ° C, 12 h, mean heating rate: 160 ° C / h, mean cooling rate: 140 ° C / h drawing at d 0.25 mm and stress-relieving annealing
  • Second diffusion annealing in a bell-type furnace under ambient atmosphere at 400 ° C, 12 h, mean heating rate: 160 ° C / h, mean cooling rate: 140 ° C / h drawing at d 0.25 mm and stress-relieving annealing
  • Second diffusion annealing in a bell-type furnace under ambient atmosphere at 410 ° C, 12 h, mean heating rate: 160 ° C / h, mean cooling rate: 140 ° C / h drawing at d 0.25 mm with a cross-section reduction of 18% per drawing stage and subsequent stress relief annealing
  • Second diffusion annealing in a bell-type furnace under ambient atmosphere at 410 ° C, 12 h, mean heating rate: 160 ° C / h, mean cooling rate: 140 ° C / h - drawing at d 0.25 mm with a cross-section reduction of 10% per drawing step and then Stress relief annealing
  • Table 1 shows the relative cutting performance achieved with each wire electrode during electrical discharge machining in the main cut and during machining with main cut and 3 recuts.
  • the electrical discharge machining was carried out on a commercially available wire EDM machine with deionized water as the dielectric.
  • a 50 mm high workpiece made of hardened cold steel of the type X155CrVMo12-1 was machined.
  • a square with an edge length of 15 mm was chosen as the cutting contour.
  • a technology available on the machine for bare brass wires with the composition CuZn37 was selected as the processing technology.
  • Comparative sample V2 has a continuously closed jacket layer made of ß-brass. Compared to comparison sample V1, the cutting performance is increased by 8% or 10%.
  • Comparative pattern V3 has a cladding layer made up of block-like particles. The block-like particles consist mainly of g-brass. With this comparison sample, the cutting performance is increased by 10% or 12% compared to comparison sample V1.
  • Comparative sample V4 has an inner jacket layer made of ⁇ -brass and an outer jacket layer made of a fine-grain phase mixture of ⁇ -brass and g-brass.
  • the thickness of the zinc layer on the output wire of comparative sample 4 is four times as high as the thickness of the zinc layer on the output wire of the comparative samples V2 and V3 and the inventive samples E1 and E2. With comparison sample V4, the cutting performance is increased by 19% or 24% compared to comparison sample 1.
  • the sample E1 according to the invention has a jacket layer with an inner, continuous area made of brass with a zinc content of 39-43% by weight and outwardly block-like particles, which are separated from one another or over at least part of their circumference through cracks and depressions (gaps). are spatially separated from the material of the jacket layer, these particles having a zinc content of 43-48 Have wt .-%.
  • the thickness of the block-like particles, measured in the radial direction on a wire cross-section, is 5-11 gm.
  • a part of the cladding layer is surrounded by a cover layer which essentially consists entirely of zinc oxide.
  • the thickness of this top layer is 0.05-0.5 gm.
  • the pattern has zinc oxide along the surface formed by the depressions (crevices) and cracks and on the surface formed by cracks which the block-like particles themselves have on.
  • the cutting performance is increased by 43% or 26% compared to comparison sample 1.
  • the increase in cutting performance with this sample is significantly greater than with comparison samples V2 and V3.
  • the cutting performance is even higher than in the case of comparison sample V4, the zinc layer thickness of which is four times that of sample E1 according to the invention.
  • the inventive pattern E2 has a jacket layer with an inner, continuous area made of brass with a zinc content of 39-43% by weight and outwardly block-like particles, which are partially or completely separated from one another or from the adjoining material by cracks and depressions (gaps) the one layer are spatially separated, with these particles having a zinc content of 43-48% by weight.
  • a part of the outer surface of the cladding layer is surrounded by a cover layer which is formed essentially entirely from zinc oxide.
  • the thickness of this top layer is 0.05-0.5 ⁇ m.
  • the pattern has zinc oxide along the surface formed by the cracks and cracks and on the surface formed by the cracks which the block-like particles themselves have.
  • the cladding layer initially produced made of predominantly g-brass, is less strongly torn and fissured. Since the g-brass is converted into ⁇ -brass in the second diffusion annealing process, the brittleness of the block-like particles decreases, so that the surface structure of the inventive pattern E2 is less fissured despite the greater deformation in the second drawing process and the thickness of the block-like particles is more uniform.
  • the thickness of the blocky particles measured in the radial direction on a wire cross-section is 9-11 ⁇ m.
  • the pattern E3 has a jacket layer with an inner, continuous area made of brass with a zinc content of 39-43% by weight and outwardly block-like particles, which are separated from one another or at least over part of their circumference through cracks and depressions (gaps). are spatially separated from the material of the jacket layer, these particles having a zinc content of 43-48 Have wt .-%.
  • the thickness of the block-like particles, measured in the radial direction on a wire cross-section, is 5-11 gm.
  • a part of the cladding layer is surrounded by a cover layer that consists predominantly of zinc oxide.
  • the thickness of this top layer is 0.05-2 gm.
  • the pattern has zinc oxide along the surface formed by the recesses (crevices) and cracks and on the surface formed by cracks which the block-like particles themselves have .
  • the cutting performance is increased by 37% or 24% compared to comparison sample 1.
  • the pattern E4 according to the invention has a jacket layer with an inner, continuous area made of brass with a zinc content of 39-43% by weight and outwardly block-like particles, which are partially or completely separated by cracks and depressions (gaps) from each other or from the adjacent material the one layer are spatially separated, with these particles having a zinc content of 43-48% by weight.
  • a part of the outer surface of the cladding layer is surrounded by a cover layer which is formed essentially entirely from zinc oxide. The thickness of this top layer is 0.05 - 2 pm.
  • pattern E4 Due to the lower cross-section reduction in the final drawing process compared to pattern E3, pattern E4 has areas on the surface with a lamellar-like structure, such that alternating lamellas formed from the cover layer, which predominantly comprises zinc oxide, and formed from the material of the block-like Particles that have a copper-zinc alloy are arranged side by side.
  • the pattern E4 includes zinc oxide along the surface formed by the cracks and cracks and on the surface formed by the cracks which the block-like particles themselves have.
  • the thickness of the block-like particles measured in the radial direction on a wire cross-section is 9-11 ⁇ m.
  • the samples E1 to E4 according to the invention have a significantly smaller overall thickness of the jacket layer than sample V4. This favors the straightness and flexural rigidity of the wire electrode, so that the automatic threading processes on the erosion machines even under difficult conditions, e.g. high work pieces, run smoothly
  • the jacket layer of the inventive samples E1 to E4 is compared to the comparative samples V3 and V4 due to the predominant or complete conversion of the g-brass to ß-brass overall more ductile and softer and thus behaves more abrasion-resistant when running on a wire EDM, so that the Process is less prone to malfunctions or impairments caused by deposits of wire abrasion.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Electrochemistry (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Crystallography & Structural Chemistry (AREA)
  • Thermal Sciences (AREA)
  • Physics & Mathematics (AREA)
  • Electrical Discharge Machining, Electrochemical Machining, And Combined Machining (AREA)
  • Non-Insulated Conductors (AREA)

Abstract

L'invention concerne un fil-électrode pour découpage par électro-érosion, le fil-électrode étant pourvu d'une âme (2) qui présente un métal ou un alliage métallique et d'une gaine (3, 4, 6) qui entoure l'âme (2) et qui comprend une ou plusieurs couches (3, 4, 6), dont une comprend des zones (3) dont la morphologie correspond à des particules du type bloc qui sont séparées dans l'espace par des fentes au moins sur une partie de leur périphérie les unes des autres, du matériau de la couche entourant ces zones, du matériau d'une ou de plusieurs autres couches et/ou du matériau de l'âme. L'invention est caractérisée en ce que, vue dans une coupe transversale de fil perpendiculairement ou parallèlement à l'axe longitudinal du fil, la partie, égale à plus de 50 %, de la surface d'une zone ayant la morphologie d'une particule du type bloc présente un alliage cuivre-zinc ayant une concentration de zinc de 38 à 49 % en poids, une mince couche de recouvrement constituée à plus de 50 % en poids d'oxyde de zinc dans une épaisseur de 0,05 - 2 µm se trouvant éventuellement sur les particules du type bloc, cette couche de recouvrement présentant des zones dans lesquelles les alliages cuivre-zinc, lesquels présentent les particules du type bloc, font saillie sur la surface. L'invention concerne également un procédé pour la fabrication dudit fil-électrode.
EP20723174.7A 2019-05-10 2020-05-08 Fil-électrode pour découpage par électro-érosion et procédé pour la fabrication dudit fil-électrode Pending EP3924129A1 (fr)

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EP19173932 2019-05-10
EP20151302 2020-01-10
PCT/EP2020/062930 WO2020229365A1 (fr) 2019-05-10 2020-05-08 Fil-électrode pour découpage par électro-érosion et procédé pour la fabrication dudit fil-électrode

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US (1) US20220212277A1 (fr)
EP (1) EP3924129A1 (fr)
JP (1) JP2022531909A (fr)
KR (1) KR20220019693A (fr)
CN (1) CN113811415B (fr)
BR (1) BR112021022537A2 (fr)
CA (1) CA3137406A1 (fr)
MX (1) MX2021013202A (fr)
WO (1) WO2020229365A1 (fr)

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KR20210038172A (ko) * 2019-09-30 2021-04-07 (주) 이디엠투데이베타알앤디센타 방전가공용 전극선
CA3167136A1 (fr) 2020-03-31 2021-10-07 Berkenhoff Gmbh Electrode a fil pour decoupe par electroerosion
TWI784706B (zh) * 2021-09-10 2022-11-21 德商貝肯赫佛股份有限公司 用於電火花沖蝕切割的線狀電極
CN115093894B (zh) * 2022-07-12 2023-07-25 四川轻化工大学 电火花加工切割工作液制备方法、工作液、铝合金表面改性方法及铝合金复合材料
CN115846777A (zh) * 2022-11-29 2023-03-28 宁波博德高科股份有限公司 一种电火花放电加工用电极丝及其制备方法

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FR2679806B1 (fr) * 1991-08-02 1995-04-07 Trefimetaux Electrode en alliage de cuivre a hautes performances pour usinage par electroerosion et procede de fabrication.
US5945010A (en) 1997-09-02 1999-08-31 Composite Concepts Company, Inc. Electrode wire for use in electric discharge machining and process for preparing same
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EP1295664B1 (fr) 2001-09-21 2008-03-26 Berkenhoff GmbH Fil-électrode pour usinage par électroérosion
FR2833875B1 (fr) 2001-12-21 2004-07-02 Thermocompact Sa Fil pour electroerosion a grande vitesse d'usinage
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KR100543847B1 (ko) * 2005-04-01 2006-01-20 주식회사 엠에이씨티 방전가공용 전극선 및 그 제조 방법
KR20070075516A (ko) 2006-01-13 2007-07-24 (주)징크젯 방전가공용 전극선의 제조방법 및 그 구조
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MX2021013202A (es) 2022-03-11
WO2020229365A1 (fr) 2020-11-19
JP2022531909A (ja) 2022-07-12
CA3137406A1 (fr) 2020-11-19
CN113811415A (zh) 2021-12-17
BR112021022537A2 (pt) 2021-12-28
KR20220019693A (ko) 2022-02-17
CN113811415B (zh) 2024-10-25

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