JP6089129B2 - 放電加工用電極線の製造方法 - Google Patents
放電加工用電極線の製造方法 Download PDFInfo
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- JP6089129B2 JP6089129B2 JP2016035869A JP2016035869A JP6089129B2 JP 6089129 B2 JP6089129 B2 JP 6089129B2 JP 2016035869 A JP2016035869 A JP 2016035869A JP 2016035869 A JP2016035869 A JP 2016035869A JP 6089129 B2 JP6089129 B2 JP 6089129B2
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- 238000003754 machining Methods 0.000 title claims description 84
- 238000004519 manufacturing process Methods 0.000 title claims description 24
- 239000000956 alloy Substances 0.000 claims description 162
- 229910045601 alloy Inorganic materials 0.000 claims description 147
- 229910052751 metal Inorganic materials 0.000 claims description 130
- 239000002184 metal Substances 0.000 claims description 130
- 238000000034 method Methods 0.000 claims description 53
- 238000007747 plating Methods 0.000 claims description 47
- HCHKCACWOHOZIP-UHFFFAOYSA-N Zinc Chemical compound [Zn] HCHKCACWOHOZIP-UHFFFAOYSA-N 0.000 claims description 40
- 239000011701 zinc Substances 0.000 claims description 40
- 229910052725 zinc Inorganic materials 0.000 claims description 40
- 229910001369 Brass Inorganic materials 0.000 claims description 39
- 239000010951 brass Substances 0.000 claims description 39
- 239000010419 fine particle Substances 0.000 claims description 36
- 239000000463 material Substances 0.000 claims description 32
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims description 29
- 229910052802 copper Inorganic materials 0.000 claims description 28
- 239000010949 copper Substances 0.000 claims description 28
- 229910000881 Cu alloy Inorganic materials 0.000 claims description 15
- 238000009792 diffusion process Methods 0.000 claims description 14
- 238000007598 dipping method Methods 0.000 claims description 14
- 238000010438 heat treatment Methods 0.000 claims description 14
- 238000009713 electroplating Methods 0.000 claims description 9
- 229910052782 aluminium Inorganic materials 0.000 claims description 8
- ATJFFYVFTNAWJD-UHFFFAOYSA-N Tin Chemical compound [Sn] ATJFFYVFTNAWJD-UHFFFAOYSA-N 0.000 claims description 7
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims description 7
- 229910052718 tin Inorganic materials 0.000 claims description 7
- 239000000126 substance Substances 0.000 claims description 4
- 238000007654 immersion Methods 0.000 claims description 2
- 239000010410 layer Substances 0.000 description 160
- 230000008569 process Effects 0.000 description 36
- TVZPLCNGKSPOJA-UHFFFAOYSA-N copper zinc Chemical compound [Cu].[Zn] TVZPLCNGKSPOJA-UHFFFAOYSA-N 0.000 description 32
- 238000006243 chemical reaction Methods 0.000 description 21
- 238000012545 processing Methods 0.000 description 19
- 230000008016 vaporization Effects 0.000 description 14
- 238000009834 vaporization Methods 0.000 description 14
- 239000000428 dust Substances 0.000 description 10
- 230000000694 effects Effects 0.000 description 9
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 9
- 229910001297 Zn alloy Inorganic materials 0.000 description 8
- 238000005452 bending Methods 0.000 description 8
- 238000005246 galvanizing Methods 0.000 description 6
- 230000009471 action Effects 0.000 description 5
- 238000010586 diagram Methods 0.000 description 5
- 230000003746 surface roughness Effects 0.000 description 5
- NLXLAEXVIDQMFP-UHFFFAOYSA-N Ammonia chloride Chemical compound [NH4+].[Cl-] NLXLAEXVIDQMFP-UHFFFAOYSA-N 0.000 description 4
- 239000002253 acid Substances 0.000 description 4
- 238000005238 degreasing Methods 0.000 description 4
- 238000009760 electrical discharge machining Methods 0.000 description 4
- 239000002360 explosive Substances 0.000 description 4
- 239000012530 fluid Substances 0.000 description 4
- 230000004907 flux Effects 0.000 description 4
- 239000007788 liquid Substances 0.000 description 4
- 239000007787 solid Substances 0.000 description 4
- 238000002844 melting Methods 0.000 description 3
- 230000008018 melting Effects 0.000 description 3
- 235000019270 ammonium chloride Nutrition 0.000 description 2
- 238000004140 cleaning Methods 0.000 description 2
- 238000001816 cooling Methods 0.000 description 2
- 230000008878 coupling Effects 0.000 description 2
- 238000010168 coupling process Methods 0.000 description 2
- 238000005859 coupling reaction Methods 0.000 description 2
- 238000005520 cutting process Methods 0.000 description 2
- 239000012634 fragment Substances 0.000 description 2
- 230000006872 improvement Effects 0.000 description 2
- 239000002245 particle Substances 0.000 description 2
- 238000004804 winding Methods 0.000 description 2
- ZOKXTWBITQBERF-UHFFFAOYSA-N Molybdenum Chemical compound [Mo] ZOKXTWBITQBERF-UHFFFAOYSA-N 0.000 description 1
- 229910000831 Steel Inorganic materials 0.000 description 1
- 230000002411 adverse Effects 0.000 description 1
- 230000008901 benefit Effects 0.000 description 1
- 238000007796 conventional method Methods 0.000 description 1
- -1 copper or brass Chemical compound 0.000 description 1
- 239000012792 core layer Substances 0.000 description 1
- 229910003460 diamond Inorganic materials 0.000 description 1
- 239000010432 diamond Substances 0.000 description 1
- 238000007599 discharging Methods 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- PCHJSUWPFVWCPO-UHFFFAOYSA-N gold Chemical compound [Au] PCHJSUWPFVWCPO-UHFFFAOYSA-N 0.000 description 1
- 229910052737 gold Inorganic materials 0.000 description 1
- 239000010931 gold Substances 0.000 description 1
- 238000003780 insertion Methods 0.000 description 1
- 230000037431 insertion Effects 0.000 description 1
- 239000000155 melt Substances 0.000 description 1
- 150000002739 metals Chemical class 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 229910052750 molybdenum Inorganic materials 0.000 description 1
- 239000011733 molybdenum Substances 0.000 description 1
- 238000000926 separation method Methods 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
- 239000011573 trace mineral Substances 0.000 description 1
- 235000013619 trace mineral Nutrition 0.000 description 1
- WFKWXMTUELFFGS-UHFFFAOYSA-N tungsten Chemical compound [W] WFKWXMTUELFFGS-UHFFFAOYSA-N 0.000 description 1
- 229910052721 tungsten Inorganic materials 0.000 description 1
- 239000010937 tungsten Substances 0.000 description 1
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- 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
- B23H1/00—Electrical discharge machining, i.e. removing metal with a series of rapidly recurring electrical discharges between an electrode and a workpiece in the presence of a fluid dielectric
- B23H1/04—Electrodes specially adapted therefor or their manufacture
- B23H1/06—Electrode material
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
- B21C1/00—Manufacture of metal sheets, metal wire, metal rods, metal tubes by drawing
- B21C1/003—Drawing materials of special alloys so far as the composition of the alloy requires or permits special drawing methods or sequences
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
- B21C23/00—Extruding metal; Impact extrusion
- B21C23/22—Making metal-coated products; Making products from two or more metals
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
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- B21C37/00—Manufacture of metal sheets, bars, wire, tubes or like semi-manufactured products, not otherwise provided for; Manufacture of tubes of special shape
- B21C37/04—Manufacture of metal sheets, bars, wire, tubes or like semi-manufactured products, not otherwise provided for; Manufacture of tubes of special shape of bars or wire
- B21C37/042—Manufacture of coated wire or bars
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- 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
- B23H1/00—Electrical discharge machining, i.e. removing metal with a series of rapidly recurring electrical discharges between an electrode and a workpiece in the presence of a fluid dielectric
- B23H1/04—Electrodes specially adapted therefor or their manufacture
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- 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
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- 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
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
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- C22C9/00—Alloys based on copper
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- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
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- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
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- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
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- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
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- C—CHEMISTRY; METALLURGY
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- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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Description
加工物搬送装置は、図面の矢印方向即ち、電極線2に対して直交する方向に移動し、電極線2は供給リール3から連続的に送出され、加工物の両端のガイドローラ5、5′を経て巻取リール4に巻き取られる。
黄銅合金の亜鉛含量が高いほど加工速度は向上すると思われるが、亜鉛含量が40%を超えると脆弱なβ相が形成されるので、細線にするときに引抜きが容易ではないという問題点がある。
このように形成された引張強度が低い芯線、即ち、相対的に軟らかい黄銅芯線が、延伸工程で発生する圧力によって、合金層のクラックを通じて溶岩湧出形状に亜鉛銅合金を突き抜いて表面の方へ迫り上がって亜鉛銅合金の細片粒を囲んだり覆うように形成することによって、放電加工のとき、加工速度は維持しながら細塵または細片屑の発生量が減る放電加工用電極線を提供することを目的にする。
本発明の他の目的は、このように電極線の表面に線材の長手方向に対して直角方向に、幅より長さが少なくとも2倍以上の長さの細片粒を形成することによって、放電加工のとき加工物の面粗度を向上させ、電極線の微塵発生を抑制するとともに速い加工速度を維持することができる放電加工用電極線を提供することである。
また、少なくとも前記第2合金材の細片粒は、前記芯線材質によって囲まれる形態を含むことを特徴とする。
また、前記メッキは、電気メッキ、溶融メッキまたは化学メッキ方法を利用する。
また、前記細片粒を形成する段階の放電加工用電極線を第2直径に細線して引抜きする前に該放電加工用電極線を上、下、左、右の何れか一方または複数の方向から曲げたりツイストさせる工程を追加することを特徴とする。
図2は、本発明の放電加工用電極線の製造方法を示す図である。先ず、図2に示すように、0.9〜1.2mm直径の銅65重量%、亜鉛35重量%からなる黄銅芯線12が提供される。
前記メッキ槽を通す方法の外に、電気メッキまたは化学メッキ方法等を利用して、3〜10μmほどの厚さに亜鉛がメッキされた黄銅の芯線を10〜60Vの電圧と100〜600m/minの速度で熱処理して、亜鉛メッキされた芯線12の引張強度を500N/mm2以下、延伸率は5%以上になるように形成することができる。
前記細線は、熱処理工程を経て機械的な性質をさらに安定化させることができる。
従って、このような亜鉛合金線材を放電加工用電極線として細線にするとき、芯線と合金層との間の延伸率の差によって合金層にクラックを容易に形成することができる。
中間線材、即ち、銅65重量%と亜鉛35重量%の成分比を有する黄銅線を直径0.9mmの芯線(第1金属)として準備する。
前記芯線に第2金属である亜鉛を利用して溶融亜鉛メッキを行なう。
溶融亜鉛メッキの工程に利用される芯線を、アルカリ脱脂槽に浸漬、水洗い、酸性洗浄し、再び水洗いした後、塩化アンモニウムフラックス槽に浸漬する。
中間線材、即ち、銅65重量%と亜鉛35重量%の成分比を有する黄銅線を、直径0.9mmの芯線(第1金属)として準備する。
前記芯線に第2金属である亜鉛を利用して溶融亜鉛メッキを行なう。
溶融亜鉛メッキの工程に利用される芯線を、アルカリ脱脂槽に浸漬、水洗い、酸性洗浄し、再び水洗いした後、塩化アンモニウムフラックス槽に浸漬する。
このように高温のメッキ槽に浸漬して溶融亜鉛メッキを行なうと、芯線が溶融亜鉛槽に浸漬されている間に該芯線の境界面から亜鉛との相互拡散反応によって銅亜鉛の合金層を構成する第1合金層22が形成され、その合金層の外郭には亜鉛銅の合金層を構成する第2合金層23が形成されるとともに軟質の芯線が製造される。
前記溶融亜鉛メッキおよび相互拡散によって、芯線表面の境界面には1〜3μmの銅亜鉛合金層からなる第1合金層が形成され、最外郭には3〜10μmの亜鉛銅合金層からなる第2合金層が形成される。
細線工程の前に中間線材をジグザグに曲げるツイスト装置33に通した後、前記中間線材は、引抜き細線工程を経て0.07〜0.35mmの直径を有する細線に製造される。
中間線材、即ち、銅65重量%と亜鉛35重量%の成分比を有する黄銅線を直径0.9mmの芯線(第1金属)として準備する。
前記芯線に第2金属である亜鉛を利用して電気亜鉛メッキを行なう。
電気亜鉛メッキ工程に利用される芯線は、アルカリ脱脂槽に浸漬、水洗い、酸性洗浄され、再び水洗いされた後、電気亜鉛メッキ槽に通される。
前記亜鉛銅の第2合金層は、一番硬度が高い部分であり、軟線の芯線より延伸率が低い。
前記引抜きされた細線の第2合金層は、芯線より硬度が高く延伸率が低いので引抜き細線の工程中に第2合金層が形成されている最外郭層の表面に多数のクラックが発生し、第2合金層は第1合金層を介して芯線の第1金属と界面をなす。
前記細線工程によって加工された放電加工用電極線は、300〜600℃の温度雰囲気で0.05〜3秒ぐらい再び熱処理を行なって芯線の機械的な性質を安定化させる。
中間線材、即ち、銅65重量%と亜鉛35重量%の成分比を有する黄銅線を、直径0.9mmの芯線(第1金属)として準備する。
前記芯線に第2金属である亜鉛を利用して電気亜鉛メッキを行なう。
電気亜鉛メッキ工程に利用される芯線は、アルカリ脱脂槽に浸漬、水洗い、酸性洗浄され、再び水洗いされた後、電気亜鉛メッキ槽に通される。
前記電気亜鉛メッキされた中間線材は、熱処理機に投入されて50〜60Vの電圧から155m/minの速度で熱処理されて、引張強度は500N/mm2以下、延伸率は5%以上になる芯線を製造する。
前記亜鉛銅の第2合金層は、一番硬度が高い部分であり、軟線の芯線より延伸率が低い。
細線の前に中間線材をジグザグに曲げるツイスト装置33に通した後、前記中間線材は、引抜き細線工程を経て0.07〜0.35mmの直径を有する細線に製造される。
前記細線工程によって加工された放電加工用電極線は、300〜600℃の温度雰囲気で0.05〜3秒ぐらい再び熱処理を行なって芯線の機械的な性質を安定化させる。
また、第1金属としては、黄銅の他に銅、銅合金を利用することができ、第2金属としては、亜鉛、アルミニウム、錫またはその合金などを利用しても良い。
上述した本発明の実施形態は、本発明の技術構成および製造方法を限定するものではなく、本発明の技術思想および目的を外れない範囲内で様々に変更して実施することができる。
2 電極線
3 供給リール
4 巻取リール
5、5′、16、16′、18 ローラ
6 電源供給装置
7 スタート穴
10 メッキ槽
12 芯線(中間線材)
14 引抜き装置
22 第1合金層
23 第2合金層
33 ツイスト装置
Claims (5)
- 第1金属からなる第1直径の線材を芯線として提供する段階と;
前記芯線に第2金属を利用してメッキする段階と、
前記メッキされた芯線を引張強度は500N/mm2以下、延伸率は5%以上に形成するとともに前記芯線と前記第2金属との相互拡散によって少なくとも前記芯線と第2金属との境界部に形成される第1合金層と、前記第1金属が前記第2金属の方向に拡散されて前記第1合金層の外郭に第2合金層が形成されるように熱処理する段階と、
前記第1合金層、第2合金層、芯線を含む放電加工用電極線を第2直径に形成するための細線工程で、前記放電加工用電極線の表面に前記芯線材が第2合金層に形成されるクラックを通じて迫り上がって少なくとも前記芯線材、前記第2合金材からなる細片粒を形成する段階を含むことを特徴とする放電加工用電極線の製造方法。 - 前記放電加工用電極線の表面に細片粒を形成する段階で、前記芯線材が迫り上がるとき前記第1合金材がともに迫り上がって、前記芯線材、前記第1合金材、前記第2合金材からなる細片粒を形成することを特徴とする請求項1に記載の放電加工用電極線の製造方法。
- 前記メッキは、電気メッキ、溶融メッキまたは化学メッキ方法を利用することを特徴とする請求項1または請求項2に記載の放電加工用電極線の製造方法。
- 前記メッキは、溶融メッキであり、前記熱処理段階は、メッキ槽の入り口温度を550〜700℃、出口温度を420〜500℃とし、1〜10秒の浸漬時間の範囲内で前記芯線をメッキ槽に通すことを特徴とする請求項3に記載の放電加工用電極線の製造方法。
- 前記第1金属は銅、黄銅または銅合金を利用し、前記第2金属は亜鉛、アルミニウム、錫またはその合金を利用することを特徴とする請求項1または請求項2に記載の放電加工用電極線の製造方法。
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