JP5107507B2 - Wire for wire electric discharge machine - Google Patents
Wire for wire electric discharge machine Download PDFInfo
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- JP5107507B2 JP5107507B2 JP2005101025A JP2005101025A JP5107507B2 JP 5107507 B2 JP5107507 B2 JP 5107507B2 JP 2005101025 A JP2005101025 A JP 2005101025A JP 2005101025 A JP2005101025 A JP 2005101025A JP 5107507 B2 JP5107507 B2 JP 5107507B2
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- wire
- discharge
- coating layer
- electric discharge
- core material
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Description
本発明は、ワイヤ放電加工機において、電極工具として使用される電極線、特に微細、精密加工用に供される、芯材（鋼線）の周囲に被覆層（たとえばブラスメッキ）が形成された電極線（以下「ワイヤ」という）に関する。 According to the present invention, in a wire electric discharge machine, a coating layer (for example, brass plating) is formed around an electrode wire used as an electrode tool, particularly a core material ( steel wire ) used for fine and precision machining. The present invention relates to an electrode wire (hereinafter referred to as “wire”).
従来、この種のワイヤとして、例えば特許文献１に記載のものが知られている。
このワイヤは、図１に示すように、芯材としての鋼線１の周囲に被覆層としてのブラスメッキ２が施された構成となっている。
As shown in FIG. 1, this wire has a structure in which brass plating 2 as a coating layer is applied around a steel wire 1 as a core material.
ところで、従来、上記のような構成のワイヤは広く使用されているものの、ブラスメッキの厚さ（被覆層の厚さ）についての理論的検討は殆ど行われていないというのが現状であり、特に、加工性能とメッキ層（被覆層）の最適厚さとの関係については、全く研究されていない。従って、従来のワイヤには、過度の厚さのブラスメッキが施されており、その分（メッキ）コストが高くなり、さらにワイヤにおける芯材の割合が必要以上に少ないため、芯材の強度を最大限活用できない、という課題がある。
本発明は、このような従来のワイヤにおける課題を解決しようとするものである。
By the way, although the wire having the above-described configuration has been widely used in the past, there is almost no theoretical study on the thickness of the brass plating (the thickness of the coating layer). The relationship between the processing performance and the optimum thickness of the plating layer (coating layer) has not been studied at all. Therefore, the conventional wire is subjected to brass plating with an excessive thickness, which increases the (plating) cost and further reduces the ratio of the core material in the wire more than necessary. There is a problem that it cannot be utilized to the maximum extent.
The present invention seeks to solve the problems associated with such conventional wires.
本発明者は、型彫り放電加工機の単発放電により被覆層と同じ材料製のワーク（被覆層がたとえばブラスメッキの時はブラス製のワーク）に単発放電痕を形成し、その「放電エネルギー」と「放電痕の平均深さおよび直径」とを計測することにより、芯材の周囲に形成される被覆層（たとえばブラスメッキ層）の最適被覆厚さが理論的に算出できるということを見いだした。そして、この理論を実際の製品に適用して、芯材の周囲に形成される被覆層の最低厚さを算出することを課題解決の手段とする。 The inventor forms a single discharge mark on a workpiece made of the same material as the coating layer by a single discharge of the die-sinking electric discharge machine (a brass workpiece when the coating layer is, for example, brass plating), and the “discharge energy” And the “average depth and diameter of discharge traces” were measured, and it was found that the optimum coating thickness of the coating layer (for example, brass plating layer) formed around the core material can be theoretically calculated. . Then, applying this theory to an actual product and calculating the minimum thickness of the coating layer formed around the core material is a means for solving the problem.
具体的には、芯材と、同芯材の周囲に形成された被覆層とからなるワイヤ放電加工機用
の直径０．０２ｍｍ〜０．５ｍｍのワイヤにおいて、型彫り放電加工機の単発放電により被覆層と同じ材料製のワーク（被覆層が例えばブラスメッキの時はブラス製のワーク）に形成された単発放電痕の平均深さをＨave とし、型彫り放電加工機の単発放電により上記ワークに形成された単発放電痕の面積をScとし、放電周波数をFpとし、単位時間当たりのワイヤ進行方向の表面積をΔSとし、ワイヤ表面における放電痕の重なる割合ＸをＸ＝Sc・Fp／ΔS とした場合、上記被覆層の最小厚さＴｂmin が、数式Ｔｂmin ＝Ｈave ・Ｘにより算出されるという理論式により、上記被覆層の最小厚さＴｂmin を算出することで課題解決の手段とする。
Specifically, in a wire having a diameter of 0.02 mm to 0.5 mm for a wire electric discharge machine composed of a core material and a coating layer formed around the same core material, by single discharge of the die- sinking electric discharge machine The average depth of single discharge traces formed on a workpiece made of the same material as the coating layer (for example, a brass workpiece when the coating layer is brass-plated) is set to Have, and the above-mentioned workpiece is formed by single discharge of a die-sinking electric discharge machine. The area of the formed single discharge mark is Sc, the discharge frequency is Fp, the surface area in the wire traveling direction per unit time is ΔS, and the overlapping ratio X of the discharge mark on the wire surface is X = Sc · Fp / ΔS In this case, the minimum thickness Tbmin of the coating layer is calculated by the theoretical formula that the minimum thickness Tbmin of the coating layer is calculated by the formula Tbmin = Have · X.
本発明によれば、放電に必要な被覆層の最低厚さを数式により算出できるので、ワイヤ
の周囲に形成される被覆層の厚さを最低厚さに抑えることが可能となる。その結果、被覆
層形成コスト（たとえばメッキコスト）を低減でき、製品単価を安くしながら、高加工性
能のワイヤを得ることが可能となる。また、芯材としての鋼の割合いを必要以上に少なく
することがないため、ワイヤの強度を保つことができ、バランスのとれた電極線を製造す
ることが可能となる。特に、ワイヤが、直径０．０２mm〜０．５mmの極細線である場合、芯材の強度を最大限活用できるので、極めて効果的である。
According to the present invention, since the minimum thickness of the coating layer necessary for the discharge can be calculated by a mathematical expression, the thickness of the coating layer formed around the wire can be suppressed to the minimum thickness. As a result, the coating layer forming cost (for example, plating cost) can be reduced, and a wire with high processing performance can be obtained while reducing the unit price of the product. Moreover, since the ratio of steel as a core material is not reduced more than necessary, the strength of the wire can be maintained, and a balanced electrode wire can be manufactured. In particular, when the wire is a very thin wire having a diameter of 0.02 mm to 0.5 mm , the strength of the core material can be utilized to the maximum, which is extremely effective.
以下、被覆層がブラスメッキで形成されるワイヤを例にして本発明の実施形態を説明する。
図２は型彫り放電加工機１０の放電加工部を模試的に示すものであり、この実施形態では、ワーク３は（被覆層と同じ材料の）ブラス製であり、ワイヤピン（電極）４は鋼からなる。符号５はこの放電加工機１０によってワーク３の上面に形成された放電痕を示している。
Hereinafter, an embodiment of the present invention will be described with reference to a wire in which a coating layer is formed by brass plating.
FIG. 2 schematically shows an electric discharge machining portion of the die-sinking electric discharge machine 10. In this embodiment, the workpiece 3 is made of brass (of the same material as the coating layer), and the wire pin (electrode) 4 is steel. Consists of. Reference numeral 5 denotes an electric discharge mark formed on the upper surface of the work 3 by the electric discharge machine 10.
計算対象とするワイヤ放電加工機における放電加工とほぼ等しい放電エネルギ−の条件で、この型彫り放電加工機１０において単発放電を行う。この放電により、ワーク３に図３に示すような、ほぼ円錐型の放電痕５が形成される。この円錐型の放電痕５の直径Ｄと最大深さH max とを計測する（図３参照）。 A single discharge is performed in the die-sinking electric discharge machine 10 under the condition of electric discharge energy substantially equal to electric discharge machining in the wire electric discharge machine to be calculated. As a result of this discharge, a substantially conical discharge mark 5 as shown in FIG. The diameter D and the maximum depth H max of the conical discharge mark 5 are measured (see FIG. 3).
ここで、ワイヤの直径をｄとし、ワイヤの加工速度をWsとし、単位時間当たりに新たに加工に用いられるワイヤの進行方向のみの（加工面と対向する）表面積をΔS とすると、
表面積ΔS ＝π・ｄ・Ws／２
なる数式が成立する。
Here, assuming that the diameter of the wire is d, the processing speed of the wire is Ws, and the surface area in the traveling direction of the wire newly used for processing per unit time (opposite the processing surface) is ΔS,
Surface area ΔS = π · d · Ws / 2
The following mathematical formula is established.
放電痕の面積Scは、Sc＝π・Ｄ2 ／４であるから、ワイヤ表面における放電痕の重なる割合Ｘは、放電周波数をFpとすると
Ｘ＝Sc・Fp／ΔS （数式１）
となる。
Area Sc of the discharge trace is because it is Sc = π · D 2/4 , the ratio X of overlapping discharge traces in the wire surface, when the discharge frequency is Fp X = Sc · Fp / ΔS ( Equation 1)
It becomes.
放電痕の形状を、図３に示すような、逆円錐形状であると仮定すると、放電痕の平均除去深さ（平均深さ方向の長さ）Ｈave と最大深さＨmax とは、
Ｈave ＝Ｈmax ／３
なる数式で示す関係となる。
Assuming that the shape of the discharge trace is an inverted conical shape as shown in FIG. 3, the average removal depth (length in the average depth direction) Have and the maximum depth Hmax of the discharge trace are:
Have = Hmax / 3
The relationship shown by the mathematical formula
放電痕の平均除去深さ（平均深さ方向の長さ）Ｈave だけでは放電痕の重なりを勘案していないので、放電痕の平均除去深さＨave にワイヤ表面の放電痕が重なる割合Ｘを乗じることによって、実際のワイヤ放電加工時に起きている放電痕の重なりまでも考慮した数式が得られる。
つまり、Ｈave にＸを乗じた値が今回の加工条件で加工中に放電によって除去されないために必要な最小ブラスメッキ厚さＴｂmin に相当する。このことから、次の数式が得られる。
Ｔｂmin ＝Ｈave ・Ｘ（数式２）
The average removal depth (length in the average depth direction) of the discharge trace does not take into account the overlap of the discharge trace, so the average removal depth Have of the discharge trace is multiplied by the ratio X where the discharge trace on the wire surface overlaps. Thus, a mathematical formula can be obtained that takes into account even the overlap of the discharge traces occurring during actual wire electric discharge machining.
That is, the value obtained by multiplying Have by X corresponds to the minimum brass plating thickness Tbmin necessary for the current machining conditions not to be removed by electric discharge during machining. From this, the following formula is obtained.
Tbmin = Have * X (Formula 2)
次に一実例を示す。
ｄ＝０．２mm（２００μm）、Ｗｓ＝１０ｍ／min（≒１．６７×１０5μm／ｓ）、Ｄ＝９０μm、Ｆｐ＝２．２×１０4 ／ｓ、Ｈave ＝９μm を、数式１および数式２に代入すると、Ｘ＝２．６７３、Ｔｂmin ＝８．０２μm となる。
実際にメッキ厚さを変化させて複数種のワイヤを製造し、これらのワイヤについて放電によって除去されないために必要な最小ブラスメッキ厚さを計測すると約８μm であった。この数値（最小ブラスメッキ厚さが約８μm ）は、上記数式２などにより得られたメッキ厚さの値とほぼ同等である。このことは、上記の理論式が正確であることを証明するものである。
An example is shown below.
d = 0.2 mm (200 μm), Ws = 10 m / min (≈1.67 × 10 5 μm / s), D = 90 μm, Fp = 2.2 × 10 4 / s, Have = 9 μm Substituting into Equation 2, X = 2.673 and Tbmin = 8.02 μm.
When a plurality of types of wires were manufactured by actually changing the plating thickness, and the minimum brass plating thickness required for these wires not being removed by electric discharge was measured, it was about 8 μm. This numerical value (the minimum brass plating thickness is about 8 μm) is almost equal to the plating thickness value obtained by the above formula 2 or the like. This proves that the above theoretical formula is accurate.
このように、この実施形態によれば、得られたワイヤは必要以上の余分なブラスメッキを施されていないので、製造のコストダウンを図ることができる。
また、上記の実例に示すような、極細電極線の場合、ワイヤには必要以上の余分なブラ
スメッキを施されていないので、芯材（鋼）の割合が必要以上に少なくなっておらず、その結果、芯材の強度を最大限に活用することができ、芯材（鋼）の強度を保持した、バランスのとれたワイヤが得られるというような効果も得られる。
Thus, according to this embodiment, since the obtained wire is not subjected to unnecessary brass plating more than necessary, the manufacturing cost can be reduced.
In addition, in the case of an extra fine electrode wire as shown in the above example, since the wire is not subjected to unnecessary brass plating more than necessary, the ratio of the core material (steel) is not reduced more than necessary, As a result, the strength of the core material can be utilized to the maximum, and an effect that a balanced wire that maintains the strength of the core material (steel) can be obtained can be obtained.
本実施例におけるブラスメッキは、湿式メッキ、乾式メッキ（例えば、スパッタリング、イオンプレーティング等）で形成されたものである。
本発明における被覆層は、ブラスメッキに限定されるものでなく、２層以上の被覆層や複合メッキあるいはパイプで形成されていてもよい。また、上記複合層を構成する元素としては、目的に応じて、銅、亜鉛、金、アルミニウム、ニッケル等を様々に組み合わせることができる。
The brass plating in this embodiment is formed by wet plating or dry plating (for example, sputtering, ion plating, etc.).
The coating layer in the present invention is not limited to brass plating, and may be formed of two or more coating layers, composite plating, or a pipe. Moreover, as an element which comprises the said composite layer, copper, zinc, gold | metal | money, aluminum, nickel, etc. can be combined variously according to the objective.
１：鋼線（芯材）
２：鋼線（芯材）１の周囲に形成された被覆層（ブラスメッキ層）
３：ワーク
４：ワイヤピン（電極）
５：放電痕
Ｄ：放電痕５の直径
Ｈmax ：放電痕５の最大深さ
1: Steel wire (core material)
2: Coating layer (brass plating layer) formed around the steel wire (core material) 1
3: Work 4: Wire pin (electrode)
5: Discharge trace D: Diameter of discharge trace 5 Hmax: Maximum depth of discharge trace 5
Claims (1)
Ｔｂmin=Ｈave ・Ｘ
ここで、
Ｈave は、型彫り放電加工機の単発放電により上記被覆層と同じ材料製のワークに形成された単発放電痕の平均深さ。
Ｘは、型彫り放電加工機の単発放電により上記ワークに形成された単発放電痕の面積をScとし、放電周波数をFpとし、単位時間当たりのワイヤ進行方向の表面積をΔS として、数式 Ｘ＝Sc・Fp／ΔS により計算された数値。 In a wire for a wire electric discharge machine comprising a core material made of steel and a coating layer formed around the core material, the coating layer has a diameter 0 having a minimum thickness Tbmin calculated by the following equation: A wire characterized by being an extra fine wire of 0.02 mm to 0.5 mm .
Tbmin = Have ・ X
here,
Have is the average depth of single discharge marks formed on a workpiece made of the same material as the coating layer by single discharge of a die-sinking electric discharge machine.
X represents the area of the single discharge trace formed on the workpiece by single discharge of the die-sinking electric discharge machine as Sc, the discharge frequency as Fp, the surface area in the wire traveling direction per unit time as ΔS, and the formula X = Sc • Numerical value calculated by Fp / ΔS.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2005101025A JP5107507B2 (en) | 2005-03-31 | 2005-03-31 | Wire for wire electric discharge machine |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2005101025A JP5107507B2 (en) | 2005-03-31 | 2005-03-31 | Wire for wire electric discharge machine |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| JP2006281329A JP2006281329A (en) | 2006-10-19 |
| JP5107507B2 true JP5107507B2 (en) | 2012-12-26 |
Family
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| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP2005101025A Expired - Fee Related JP5107507B2 (en) | 2005-03-31 | 2005-03-31 | Wire for wire electric discharge machine |
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| Country | Link |
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2013139073A (en) * | 2012-01-06 | 2013-07-18 | Sumitomo Electric Ind Ltd | Electrode wire for wire electric discharge machining and method of manufacturing the same |
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|---|---|---|---|---|
| JP3382756B2 (en) * | 1995-07-31 | 2003-03-04 | 三菱電機株式会社 | Electric discharge machining apparatus and electric discharge machining method |
| JPH1128618A (en) * | 1997-07-04 | 1999-02-02 | Ngk Insulators Ltd | Electrode wire for wire-cut electrical discharge machining |
| JP4325844B2 (en) * | 2003-05-30 | 2009-09-02 | 金井 宏彰 | Electrode wire for wire electrical discharge machining |
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| JP2006281329A (en) | 2006-10-19 |
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