TW202037422A - Method for manufacturing metal wire and structure thereof capable of forming a crystal layer having pyroelectricity to improve the efficiency of electrical discharge machining - Google Patents

Abstract

The present invention relates to a method for manufacturing a metal wire and a structure thereof. A brass wire having a zinc content of 40% or less and a diameter of 1.2mm or more is used as a core wire. The surface of the core wire is sputtered with a coating base material having a zinc content of more than 75% for at least one time to form a coating layer on the surface of the core wire so as to complete the production of a bus-bar. The bus-bar is annealed and stretched into a metal wire having a diameter of 0.15mm-0.35mm, allowing the surface of the coating layer to show many cracks and a porous structure. During the annealing process, the bus-bar is allowed to approach the magnetic field generated by an induction coil to drive the crystal orientation of the zinc oxide layer of the coating layer to be consistent, which is beneficial to the formation of a crystal layer having pyroelectricity to improve the efficiency of electrical discharge machining.

Description

Manufacturing method and structure of metal wire

The present invention relates to a manufacturing method and structure of a metal wire, in particular to a metal wire used in a wire cutting machine.

The metal wire used in the wire cutting machine used in electrical discharge machining was mainly brass wire in the early days. However, when the brass wire is processed, the copper particles generated by vaporization will accumulate on the processing surface of the workpiece. The formation of stratification increases the thickness of the surface of the work, which affects the hardness and roughness of the work surface. In addition, when copper particles are blocked between the metal wire and the workpiece, it is easy to short-circuit or fail to cool, causing the metal wire to break.

During electrical discharge machining, if the surface of the metal wire is disintegrated or the surface has cracks or cavities, it will help the particles generated by the electrical discharge gasification to be washed out by the dielectric liquid, and the contact area between the metal wire and the dielectric liquid Increase and reduce the working temperature of the metal wire to reduce the possibility of wire breakage and increase the service life. For this reason, the metal wire galvanized on the surface of the core wire has been disclosed; the above-mentioned galvanized metal wire, due to the characteristics of zinc, forms numerous cracks or cavities on the surface during the stretching process. Therefore, when used in wire electrical discharge machining, part of the zinc in the outer layer will be vaporized into particles and disintegrated. The disintegrated vaporized particles can be carried away by the dielectric liquid along the cracks or cavities, improving the original brass wire The shortcomings of, achieve the effect of reducing disconnection and increasing work efficiency.

There are currently two types of galvanized metal wires in manufacturing. As shown in my country's M564493 and I391197, they are electroplated on the surface of a brass core wire, and a galvanized layer is attached, and then stretched and annealed to Cracks or cavities are generated on the surface of the galvanized layer. However, the above-mentioned manufacturing methods using traditional electroplating methods must discharge electrolytes, solvents, and other waste water with strong acids or alkalis, causing significant pollution to the environment.

Another manufacturing method, as shown in Chinese New Patent No. CN 1078831C or U.S. Patent No. 4,686,153, is to immerse the brass core wire in the zinc bath by immersion plating. However, this immersion plating method can reduce the traditional There is a pollution problem of electroplating wastewater, but a furnace must be equipped to melt zinc.

Whether it is electroplating or immersion plating, the surface of the zinc coating on the surface of the core wire is very smooth and flat, and only a few cracks can be found under the microscope. It must be expected that during the stretching process, More cracks on the surface. However, in fact, the depth structure of cracks and pits on the surface of the galvanized metal wire disclosed so far is not obvious. Therefore, the vaporized particles generated in the electrical discharge machining will still be laminated , Although the scourability is better than pure copper wire, there is still room for improvement.

In view of this, the inventor of the present case conducted research and revealed the manufacturing method and structure of the metal wire of the present invention.

The purpose of the present invention is to provide a method for manufacturing a metal wire, which uses a brass wire with a zinc content of less than 40% and a diameter of 1.2mm or more as the core wire, and the surface of the core wire is coated with a metal with a zinc content of more than 75% The substrate is sprayed on the core wire at least once to form a coating layer on the surface of the core wire that is composed of particles of the plated substrate after being atomized, complete the production of the bus bar, and then stretch the bus bar Into a metal wire with a diameter of 0.15mm~0.35mm.

The manufacturing method of the metal wire disclosed in the present invention uses two or more coating substrates with different zinc content on the surface of the core wire, and the core wire is sprayed at the same time, so that the coating layer formed is made of It is composed of particles after atomization of two or more coating substrates with different zinc content. The aforementioned coating substrate can be a pure zinc wire or a zinc alloy wire.

The manufacturing method of the metal wire disclosed in the present invention, wherein the core wire is preheated to 350°C~420°C before surface spraying, so that the atomized coating substrate particles can be smoothly attached or embedded in the spraying The surface of the core wire stably forms the coating layer, which is also beneficial to the formation of an α+β bidirectional crystal structure between the surface of the core wire and the coating layer.

The manufacturing method of the metal wire disclosed in the present invention, wherein the bus bar is stretched at 100℃~150℃ to a diameter of 0.8mm, and then stretched at room temperature or 200℃~300℃ to a diameter of 0.15mm~0.35mm, and then passed Anneal at 250℃~350℃ for 1~5 hours to obtain the metal wire. Because zinc is easy to be broken on the surface during the stretching process, the busbar will have cracks or holes on the surface during the forming process of stretching to 0.15mm~0.35mm. These cracks and holes will increase and The contact area of the discharge medium increases its heat dissipation, and at the same time helps the flushing of the metal wire in the electric discharge machining, which is beneficial to the elimination of processing waste and avoids the metal wire from breaking during the electric discharge machining. The above-mentioned electrical discharge machining specifically refers to Wire Electrical Discharge Machining (wire EDM).

The manufacturing method of the metal wire disclosed in the present invention makes the metal wire approach an induction coil during the annealing process, so that the induction coil can be applied with a voltage of 110V~240V. The crystalline direction of the zinc oxide layer on the cladding layer tends to be consistent by inducing the magnetic field, which is beneficial to the generation of a pyroelectric crystal layer, which is beneficial to the efficiency of electrical discharge machining.

In the method of manufacturing the metal wire disclosed in the present invention, the core wire is guided by a plurality of rollers and passes through the spraying range, that is, in a spraying process, the spraying operation of the coating layer is completed. Or the core wire is guided by a plurality of rollers and passes through the spraying range for many times, that is, the spraying operation of the coating layer is completed in the process of multiple spraying.

The manufacturing method of the metal wire disclosed in the present invention, wherein the thickness of the coating layer of the bus bar is 10 μm-100 μm.

The purpose of the present invention is to provide a metal wire structure, which contains: a core wire, which is taken from a brass wire with a zinc content of less than 40%; a coating layer attached to the surface layer of the core wire, the coating layer is made of zinc Most particles with a content greater than 75% are attached to the core wire and stretched to form. Cracks or cavities are formed on each batch of coating layers; and a pyroelectricity crystal layer is formed on the surface of the coating layer .

In the structure of the metal wire disclosed in the present invention, the cladding layer is made of two or more coating substrates with different zinc content, and the core wire is sprayed and stretched at the same time. The particles atomized by two coating substrates with different zinc content can be overlapped or mixed on the surface of the core wire.

The manufacturing method and structure of the metal wire disclosed in the present invention can be clarified by the following description and accompanying drawings.

Please refer to Figures 1 and 4, the present invention relates to a method for manufacturing a metal wire, which uses a brass wire with a zinc content of less than 40% and a diameter of 1.2mm or more as the core wire (10), and the core wire (10) The surface of the core wire (10) is sprayed at least once with a metal with a zinc content of more than 75% as the coating substrate, so as to form particles on the surface of the core wire (10) that are atomized by the coating substrate ( 21) The stacked cladding layer (20) completes the production of the bus bar, and then stretches the bus bar (L') into a metal wire (L) with a diameter of 0.15 to 0.35 mm to complete the metal wire disclosed in the present invention ( L) Finished product.

As shown in Figures 1, 4, and 5, since the method for manufacturing the metal wire disclosed in the present invention, the coating layer (20) is formed by stacking particles (21) after the coating substrate is atomized, so Between the particles (21) and the particles (21) is a combined interface or gap. When the bus bar (L') is stretched (or drawn), it is beneficial for the coating layer (20) to produce cracks or The generation of cavities (C). As shown in Fig. 5, in the metal wire formed by the present invention, the particles (21) of the coated substrate after atomization are stacked, and cracks or cavities (C) are formed between the particles.

As shown in Figures 1, 6, and 7, the manufacturing method of the metal wire disclosed in the present invention, wherein the surface of the core wire (10) is coated with two or more different zinc content coating substrates, and the core wire (10) Perform spraying, so that the formed coating layer (20) is composed of particles (21a, 21b) atomized from two or more different zinc content (all greater than 75%) of the coating substrate constitute. As shown in Figures 6 and 7, when the present invention uses two coating substrates with different zinc content, the core wire (10) is spray-plated at the same time, so that the formed coating (20) is composed of two different zinc content The particles (21a, 21b) are mixedly stacked and attached to the core wire. Due to the different zinc content, the physical properties are different. During the stretching process, the ductility produced is also different, which helps the coating layer (20) Cracks or pits are generated (C).

The manufacturing method of the metal wire disclosed in the present invention, wherein the core wire (10) is preheated to 350°C~420°C before surface spraying, so that the surface of the bus bar (L') is close to the melting point of the plating substrate , During spraying, better adhesion effect can be obtained.

The manufacturing method of the metal wire disclosed in the present invention, wherein the bus bar (L') is stretched to a diameter of 0.8mm at 100°C to 150°C, and then stretched to a diameter of 0.15mm to 0.35mm at a normal temperature of 200°C to 300°C, And after annealing at 250℃~350℃, 1~5 hours, the metal wire (L) is obtained.

The above-mentioned bus bar (L') is stretched at 100°C to 150°C for the first stage, the main purpose of which is to make the cladding layer (20) obtain better ductility and make the surface of the wire smooth. The subsequent stretching process to 0.15mm~0.35mm can be carried out at room temperature or 200℃~300℃ to cause cracks or cavities on the surface of the coating (C). According to the requirements of the conventional wire cutting machine, the wire diameter of the metal wire is usually 0.15mm, 0.2mm, 0.25mm, 0.3mm, 0.35mm, but the present invention does not limit the wire diameter of the metal wire.

The manufacturing method of the metal wire disclosed in the present invention makes the metal wire approach an induction coil during the annealing process, and the induction coil is supplied with a voltage of 110V~240V. In the annealing process, the crystals of the cladding layer (20) will be rearranged. By the approach of the magnetic field of the induction coil, the crystal directions of the zinc oxide layer on the cladding layer (20) tend to be consistent, so as to generate thermoelectricity (pyroelectricity) crystal layer to facilitate the efficiency of electrical discharge machining.

The manufacturing method of the metal wire disclosed in the present invention, as shown in FIG. 2, can make the core wire (10) guided by a plurality of rollers (30) and pass the spraying range (S) at one time to complete the spraying process. Or, as shown in Figure 3, the core wire (10) is guided by a plurality of rollers (30), and the spraying process is completed after passing through the spraying range (S) many times. One or more sprays are used to determine the thickness and uniformity of spraying.

The manufacturing method of the metal wire disclosed in the present invention, wherein the thickness of the coating layer (20) on the bus bar (L') after spraying is 10 μm-100 μm. The best is 10μm~30μm.

As shown in Figures 4-7, the structure of the metal wire disclosed in the present invention contains: a core wire (10), which is taken from a brass wire with a zinc content of less than 40%; and a coating layer (20) attached to The surface layer of the core wire (10), the coating layer (20) is composed of particles stacked after atomization of the plating base material with a zinc content of more than 75%, and is stretched and formed with the core wire (10) to cover each batch Cracks or cavities (C) are formed on the layer (20).

The structure of the metal wire disclosed in the present invention makes the cladding layer (20) approach an induced magnetic field in an annealing environment to generate a pyroelectricity crystal layer.

As shown in Figures 6 and 7, the structure of the metal wire disclosed in the present invention, wherein the cladding layer (20) is based on two or more coating substrates with different zinc content, and the core wire (10) Spraying, so that the formed coating layer (20) is composed of particles (21a, 21b) after atomization of two or more coating substrates with different zinc content.

In the structure of the metal wire disclosed in the present invention, the thickness of the coating layer (20) before being stretched is 10 μm-100 μm. The best is 10μm~30μm.

According to the manufacturing method of the metal wire disclosed in the present invention, the present invention is implemented as follows: [Example 1]: A brass wire with a zinc content of 37% and a diameter of 1.2 mm is taken as the core wire (10) and placed on the surface of the core wire (10) , Using metal with 95% zinc content as the plating base material, apply one spray plating to the core wire (10), the average thickness of the spray plating is 25μm, and after being stretched at 120°C to 0.8mm in diameter, it is pulled down at 250°C. Stretched to 0.25mm, and annealed at 250°C for 2.5 hours, the resulting metal wire (L) has a tensile strength of 1015N/mm ² after testing. The finished product meets the requirements of wire cutting wire. [Example 2]: A brass wire with a zinc content of 37% and a diameter of 1.2 mm is taken as the core wire (10), and on the surface of the core wire (10), a metal with a zinc content of 95% is used as the plating base material. ) After spraying twice, the average thickness of the spraying is 50μm, and after being stretched to 0.8mm in diameter at 120°C, it is stretched to 0.25mm at 250°C and annealed at 250°C for 1.5 hours. After testing, the tensile strength of the metal wire is 1010N/mm ² , and the finished product meets the requirements of wire cutting wire. [Example 3]: A brass wire with a zinc content of 32% and a diameter of 1.2mm is taken as the core wire (10), and on the surface of the core wire (10), a metal with a zinc content of 95% is used as the plating base material. ) Apply one spraying, the average thickness of the spraying is 10μm, and after stretching to 0.8mm in diameter at 120℃, stretching to 0.15mm at 250℃, and annealing at 250℃ for 2.5 hours, the result is The metal wire has a tensile strength of 950N/mm ² after testing, and the finished product meets the requirements of wire cutting wires. [Example 4]: A brass wire with a zinc content of 37% and a diameter of 1.2 mm is taken as the core wire (10), and on the surface of the core wire (10), a metal with a zinc content of 95% is used as the plating substrate. ) Apply one spraying, the average thickness of spraying is 30μm, and after stretching to 0.8mm in diameter at 120℃, stretching to 0.35mm at 250℃, and annealing at 250℃ for 1.5 hours. The metal wire has a tensile strength of 1050N/mm ² after testing, and the finished product meets the requirements of wire cutting wires.

The metal wire obtained according to the disclosed metal wire manufacturing method of the present invention does not use traditional electroplating in the manufacturing process, so there is no problem of electrolyte discharge and waste water discharge, which greatly reduces environmental pollution. The obtained metal wires are all compatible with wire cutting machines. According to the application requirements of the present invention, the spraying method is adopted in the present invention, which can greatly reduce the manufacturing time and show the novelty and economic value of the present invention.

The method and structure disclosed in the present invention can be modified and applied without departing from the spirit and scope of the present invention, and the present invention is not limited to the above-mentioned embodiments.

(10): core wire (20): Coating layer (21): Particles (21a)(21b): particles (C): Cracks or pits (L’): Bus (L): Metal wire (S): Spraying range

Figure 1: Block diagram of the manufacturing process of the present invention. Figure 2 is a schematic diagram of the invention using rollers to guide the bus bar through spraying. Fig. 3 is a schematic diagram of the present invention using rollers to guide the bus bar through spraying multiple times. Fig. 4 is a schematic diagram of the structure of a metal wire made by spraying a single plating substrate according to the present invention. Figure 5: is a microscope enlarged view of a metal wire made by spraying a single-plated substrate according to the present invention. Fig. 6 is a schematic diagram of the structure of a metal wire made by spraying two kinds of coating substrates according to the present invention. Fig. 7 is a microscope enlarged view of a metal wire made by spraying two kinds of coating substrates according to the present invention.

Claims (10)

A method for manufacturing metal wire, using brass wire with a zinc content of less than 40% and a diameter of 1.2mm or more as the core wire, and on the surface of the core wire, using a metal with a zinc content of more than 75% as the plating base material to apply At least one spraying to form a coating layer composed of particles stacked on the core wire after atomization of the plating layer base material to complete the production of the bus bar, and then stretch the bus bar to a diameter of 0.15mm~0.35mm metal wires. The method for manufacturing a metal wire according to claim 1, wherein on the surface of the core wire, two or more coating substrates with different zinc content are used, and the core wire is sprayed at the same time, so that the formed coating layer , Is composed of two or more particles with different zinc content after atomization of the coating substrate. The method for manufacturing a metal wire according to claim 1, wherein the core wire is preheated to 350°C to 420°C before surface spraying. The method of manufacturing a metal wire as described in claim 1, wherein the bus bar is stretched at 100~150℃ to a diameter of 0.8mm, and then stretched at room temperature or 200℃~300℃ to a diameter of 0.15mm~0.35mm, after Anneal at 250℃~350℃ for 1~5 hours to obtain the metal wire. According to the manufacturing method of the metal wire described in claim 4, the metal wire approaches the magnetic field generated by an induction coil during the annealing process. The method for manufacturing a metal wire according to claim 1, wherein the core wire is guided by a plurality of rollers, and passes through the spraying range once or through the spraying range multiple times. The method for manufacturing a metal wire according to claim 1, wherein the thickness of the coating layer of the bus bar is 10 μm-100 μm. A metal wire structure containing: a core wire, taken from a brass wire with a zinc content of less than 40%; a coating layer attached to the surface of the core wire, the coating layer is made of a coating substrate with a zinc content of more than 75% The atomized particles are stacked and formed together with the core wire to form cracks or cavities on each batch of coating layers. According to the structure of the metal wire described in claim 8, the cladding layer approaches an induced magnetic field in an annealing environment to generate a crystal layer with pyroelectricity. The structure of the metal wire according to claim 8, wherein the coating layer is made of two or more coating substrates with different zinc content, and the core wire is sprayed at the same time, so that the coating layer formed is made of Two or more coating substrates with different zinc content are stacked by particles after atomization.

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