WO2014025007A1 - ワイヤ放電加工に用いるワイヤ電極 - Google Patents

ワイヤ放電加工に用いるワイヤ電極 Download PDF

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Publication number
WO2014025007A1
WO2014025007A1 PCT/JP2013/071604 JP2013071604W WO2014025007A1 WO 2014025007 A1 WO2014025007 A1 WO 2014025007A1 JP 2013071604 W JP2013071604 W JP 2013071604W WO 2014025007 A1 WO2014025007 A1 WO 2014025007A1
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WO
WIPO (PCT)
Prior art keywords
wire
brass
wire electrode
zinc
layer
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.)
Ceased
Application number
PCT/JP2013/071604
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English (en)
French (fr)
Japanese (ja)
Inventor
上田利幸
真家信夫
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.)
Sodick Co Ltd
Original Assignee
Sodick Co Ltd
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 Sodick Co Ltd filed Critical Sodick Co Ltd
Publication of WO2014025007A1 publication Critical patent/WO2014025007A1/ja
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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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
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • 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
    • C23C10/00—Solid state diffusion of only metal elements or silicon into metallic material surfaces
    • C23C10/28—Solid state diffusion of only metal elements or silicon into metallic material surfaces using solids, e.g. powders, pastes
    • C—CHEMISTRY; METALLURGY
    • C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
    • C25D—PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
    • C25D5/00—Electroplating characterised by the process; Pretreatment or after-treatment of workpieces
    • C25D5/48—After-treatment of electroplated surfaces
    • C25D5/50—After-treatment of electroplated surfaces by heat-treatment
    • C—CHEMISTRY; METALLURGY
    • C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
    • C25D—PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
    • C25D7/00—Electroplating characterised by the article coated
    • C25D7/06—Wires; Strips; Foils
    • C25D7/0607—Wires
    • C—CHEMISTRY; METALLURGY
    • C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
    • C25D—PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
    • C25D3/00—Electroplating: Baths therefor
    • C25D3/02—Electroplating: Baths therefor from solutions
    • C25D3/22—Electroplating: Baths therefor from solutions of zinc

Definitions

  • the present invention relates to a wire electrode used for wire electric discharge machining.
  • the present invention relates to a wire electrode in which zinc in a coating layer is diffused into a brass core wire.
  • the wire electrode is a tool electrode used for wire electric discharge machining.
  • a standard wire electrode has a diameter of ⁇ 0.10 mm or more and ⁇ 0.30 mm.
  • the material of the wire electrode affects the material removal rate, surface roughness, and shape accuracy.
  • the surface roughness and the shape accuracy are simply referred to as accuracy. From the viewpoint of accuracy, the roughness of the outer peripheral surface of the wire electrode is preferably small. A wire electrode that is easily consumed by electric discharge machining adversely affects accuracy.
  • the wire electrode is vertically conveyed between a pair of wire guides.
  • An appropriate tension is applied to the traveling wire electrode. It is known that a traveling wire electrode vibrates between a pair of wire guides. The vibration of the wire electrode adversely affects accuracy. The large tension of the wire electrode suppresses unwanted vibrations. Therefore, the wire electrode requires high tensile strength. Furthermore, the wire electrode requires high heat resistance and good conductivity.
  • a typical wire electrode is made from brass.
  • a wire electrode in which zinc having a low melting point is coated on the outer peripheral surface of a brass core wire is known.
  • the zinc coating layer takes away the heat resulting from the discharge and melts and scatters.
  • the brass core wire is protected from heat. Since a high peak current can be supplied to the zinc-coated wire electrode, the material removal rate is improved.
  • the zinc coating layer is difficult to be fixed on the outer peripheral surface of the brass core wire and may be peeled off by the final wire drawing. Electroplating is difficult to form a thick zinc coating layer. In hot dipping, it is difficult to form a zinc coating layer having a small surface roughness.
  • Patent Document 1 discloses a wire electrode in which a layer in which zinc is diffused into a core wire by heat treatment is formed between a brass core wire and a zinc coating layer. This diffusion layer makes it difficult to peel off the zinc coating layer.
  • Patent Document 2 discloses a wire electrode composed of a copper alloy core wire and a diffusion layer as a surface layer by long-time heat treatment of the zinc-coated wire. This diffusion layer is an ⁇ mixed crystal composed of an ⁇ phase and a ⁇ phase. The ⁇ phase indicates a face-centered cubic lattice structure, and the ⁇ phase indicates a body-centered cubic lattice structure.
  • Patent Document 3 discloses a wire electrode obtained by subjecting a pure copper core wire coated with zinc to two heat treatments at different temperatures.
  • This wire electrode is composed of an ⁇ -phase core wire and a ⁇ -phase surface layer. If the core wire changes to ⁇ -phase brass, it becomes difficult to form a surface layer having a sufficient and uniform thickness.
  • Patent Document 4 discloses a wire electrode in which a diffusion layer of ⁇ phase, ⁇ phase, or ⁇ phase- ⁇ phase is selectively formed as a surface layer depending on heat treatment conditions.
  • the heat treatment condition is, for example, a temperature rise rate.
  • the ⁇ phase exhibits a hexagonal close-packed lattice structure with a high atomic density. It is known that the higher the atomic density in the crystal structure, the more efficient the discharge energy.
  • a wire electrode including an ⁇ -phase diffusion layer as a surface layer can theoretically improve the material removal rate without reducing accuracy.
  • the ⁇ -phase diffusion layer as the surface layer needs to have a thickness of 5 ⁇ m or more.
  • the ⁇ -phase diffusion layer has poor spreadability, is hard, and is difficult to be plastically deformed. Therefore, the thickness of the ⁇ -phase diffusion layer that remains unbroken after the final wire drawing is at most 2 ⁇ m. For this reason, the wire electrode including the ⁇ -phase diffusion layer as the surface layer cannot actually utilize the advantages.
  • the object of the present invention is to provide a wire electrode comprising a zinc-rich surface layer of sufficient thickness that can be easily manufactured.
  • the wire electrode of the present invention comprises a core wire (10) made of brass and a brass wire having a zinc coating layer formed by electroplating in a heating furnace (40) in a horizontal direction at a constant traveling speed while traveling in a horizontal direction at a predetermined constant temperature. It is formed by forming a diffusion layer consisting only of the ⁇ phase in which zinc in the zinc coating layer diffuses into the brass wire by continuously and uniformly heat-treating in an atmosphere, and then reducing the diameter of the heat-treated wire by drawing. And a surface layer (20) having a thickness of 5 ⁇ m or more.
  • the diameter of the brass wire is preferably ⁇ 0.7 ⁇ m or more and ⁇ 1.2 ⁇ m or less.
  • the thickness of the zinc coating layer is preferably 5 ⁇ m or more and 20 ⁇ m or less.
  • the brass wire on which the zinc coating layer is formed is preferably heat-treated in a constant temperature atmosphere of 450 ° C. or higher and 650 ° C. or lower. More preferably, the brass wire on which the zinc coating layer is formed is heat-treated in a constant temperature atmosphere of 540 ° C. or higher and 600 ° C. or lower. Further, the zinc content in the surface layer is 45% by weight or more and 48% by weight or less.
  • the core wire is made of brass containing 60% to 70% by weight of copper and 30% to 40% by weight of zinc.
  • the wire electrode further includes a partition layer having a thickness of 1 ⁇ m or less formed between the core wire and the surface layer.
  • FIG. 1 is a cross-sectional view showing a wire electrode of the present invention.
  • FIG. 2 is a flowchart showing a process for manufacturing the wire electrode of the present invention.
  • FIG. 3 is a side view of a heating furnace used in the process for producing the wire electrode of the present invention.
  • the wire electrode 1 of the present invention includes a core wire 10, a surface layer 20, and a partition wall layer 30.
  • the core wire 10 is brass.
  • the core wire 10 is made of brass containing 60% by weight to 70% by weight copper, 30% by weight to 40% by weight zinc, and less than 1% by weight impurities.
  • the core wire 10 having a zinc concentration exceeding 40% by weight is easily dissolved when immersed in the plating solution, and the outer shape cannot be maintained.
  • the zinc content is less than 30% by weight, the core wire 10 is insufficient in straightness.
  • the core wire 10 is made of brass containing 65% by weight copper and 35% by weight zinc.
  • the surface layer 20 is a diffusion layer.
  • the diffusion layer generally includes a ⁇ phase having a body-centered cubic lattice.
  • the zinc content of the diffusion layer is 45% by weight or more and 48% by weight. As long as the effects of the wire electrode of the present invention can be obtained, the diffusion layer is allowed to contain a little ⁇ phase or ⁇ phase.
  • the surface layer 20 is made of brass containing more than 40% by weight of zinc, so-called zinc rich brass. Particularly preferably, the surface layer 20 contains not less than 45 wt% and not more than 48 wt% of zinc.
  • the crystal structure of the body-centered cubic lattice and the high zinc content improve the material removal rate of electrical discharge machining.
  • the surface layer 20 has a thickness of at least 5 ⁇ m.
  • a zinc coating layer having a thickness of 5 ⁇ m or more and 20 ⁇ m or less is uniformly formed on the surface of the core wire of ⁇ 0.7 mm or more and ⁇ 1.2 mm or less by electroplating.
  • zinc in the coating layer diffuses into the brass core wire, and a diffusion layer having a thickness of 40 ⁇ m or more and 80 ⁇ m or less is formed.
  • the thickness of the diffusion layer is reduced to 5 ⁇ m or more and 20 ⁇ m or less.
  • the partition layer 30 is formed between the core wire and the diffusion layer under a certain heating condition in the heat treatment for changing the zinc coating layer into the ⁇ -phase diffusion layer.
  • the partition layer 30 has a thickness of 1 ⁇ m or less. Since the partition layer 30 is inside the surface layer 20, it is not affected by electric discharge and does not affect electric discharge machining performance. Since the partition wall layer 30 is extremely thin, its component and structure are not accurately analyzed. When the thickness of the diffusion layer is increased to 40 ⁇ m or more and 80 ⁇ m or less, the partition layer 30 is estimated to delay diffusion and protect the core wire.
  • the wire electrode 1 improves the material removal rate.
  • the wire electrode 1 has sufficient conductivity, tensile strength, and straightness.
  • the wire electrode 1 includes a diffusion layer that is not broken by wire drawing.
  • a wire electrode having a diameter of 0.02 mm including the core wire 10 and the surface layer 20 is manufactured.
  • the core wire 10 is made of brass containing 65% by weight copper and 35% by weight zinc.
  • the surface layer 20 is a ⁇ -phase diffusion layer and has a thickness of 5 ⁇ m and a zinc content of 46% by weight.
  • a copper plate or copper ingot and zinc powder are put into a melting furnace to produce brass.
  • the concentration of copper or zinc in the melting furnace is measured, and brass having the composition required for the core wire 10 is generated.
  • a wire is cast.
  • molten brass is continuously poured out of the melting furnace and cooled.
  • a wire having a diameter of 6 mm to 10 mm, preferably 8 mm is formed.
  • the diameter of the wire is not constant.
  • An annular convex portion such as a bamboo knot is formed on the wire.
  • undesirable small irregularities are formed on the surface of the wire.
  • the wire is reduced in diameter by drawing to form a brass wire having a diameter of ⁇ 0.7 mm to ⁇ 1.2 mm, preferably ⁇ 0.9 mm.
  • This brass wire becomes the core wire of the final wire electrode.
  • a number of dies with different inner diameters are used for wire drawing.
  • the wire is passed through a large number of dies and gradually reduced in diameter.
  • the diameter of a wire is made constant by wire drawing.
  • the diameter of the brass wire only needs to be small enough to efficiently perform electrogalvanization and heat treatment. Further, the diameter of the brass wire only needs to be small enough that the surface layer 20 is not broken when the wire is reduced to ⁇ 0.20 mm by drawing.
  • the brass wire is galvanized by an electrogalvanizing method.
  • a brass wire wound around a spool is loaded on a pay-off reel.
  • the brass wire is tensioned and conveyed at a constant traveling speed.
  • the brass wire is sent to a tank filled with alkaline electric field water for cleaning. Further, the brass wire is sent to a water cleaning device, and the alkaline cleaning liquid is washed away.
  • the brass wire is sent to an acidic electroplating bath.
  • the brass wire that has passed through the electroplating bath is sufficiently dried by a hot air heater and then wound on a winding spool. In order to form a uniform zinc coating layer, the winding speed is controlled according to the detected traveling speed.
  • a device that absorbs fluctuations in tension is provided in the vicinity of the take-up spool, and plating unevenness due to brass wire vibration is prevented.
  • the thickness of the galvanizing is 5 ⁇ m or more and 20 ⁇ m or less. If necessary, the plating is performed a plurality of times.
  • the entire surface layer 20 having a thickness of 5 ⁇ m or more is a diffusion layer having substantially only a ⁇ phase.
  • the ⁇ phase is formed in the process of changing the crystal structure of the material during the heat treatment, and the existence time thereof is short.
  • the zinc coating layer is formed by an electrogalvanizing method.
  • the electroplating method can form a uniform and smooth coating layer.
  • it is difficult to form a thick plating as compared with the hot dipping method.
  • it is difficult for a zinc coating layer that is too thick to change into a uniform ⁇ -phase diffusion layer by heat treatment.
  • the ⁇ -phase diffusion layer that is too thick has insufficient spreadability.
  • the coated wire 2 having a zinc coating layer having a thickness of 5 ⁇ m or more and 20 ⁇ m or less is continuously and uniformly heated in the heating furnace 40.
  • a covered wire 2 having a diameter of 0.7 mm or more and 1.2 mm or less is wound around a spool 8.
  • the covered wire 2 is conveyed from the spool 8 to the payoff reel 7 via the roller 5, the heating furnace 40, and the roller 6.
  • the spool 8, the roller 5, the roller 6, and the payoff reel 7 give a tension that does not sag to the covered wire 2, and the covered wire 2 is horizontally supported between the rollers 5 and 6.
  • the covered wire 2 is linearly run in the horizontal direction at a constant speed.
  • the heating furnace 40 has a long heating chamber in the traveling direction of the covered wire 2.
  • the length of the heating chamber is a few meters.
  • the cross section of the heating chamber in plan view is rectangular.
  • a plurality of electric heaters 4 are provided on the horizontal floor of the heating furnace 40.
  • the electric heater 4 is located away from the covered wire 2.
  • the shortest distance between the electric heater 4 and the covered wire 2 is 50 cm to 100 cm.
  • a large number of heaters 4 are arranged at equal intervals in the traveling direction of the covered wire 2.
  • a detector (not shown) detects the traveling speed of the covered wire 2, and the rotation of the spool 8 is controlled according to the traveling speed.
  • the temperature in the heating furnace 40 is detected by a number of thermocouples 9.
  • a large number of thermocouples 9 are provided on the ceiling of the heating furnace 40.
  • the temperature in the heating furnace 40 is strictly maintained at a predetermined value throughout.
  • the coated wire 2 is exposed to a predetermined constant temperature atmosphere for a predetermined time until the zinc coating layer becomes a diffusion layer having only a ⁇ phase.
  • the coating layer usually changes in the order of ⁇ phase, ⁇ phase, ⁇ phase, and ⁇ phase, but the heat treatment in step S5 forms a diffusion layer of only ⁇ phase.
  • the diffusion layer having only the ⁇ phase is made of brass having a zinc content of 45 wt% or more and 48 wt% or less.
  • the covered wire 2 is continuously heat-treated.
  • the appropriate traveling speed of the covered wire 2 is 2.8 m / min or more and 3.2 m / min or less.
  • the temperature in the heating furnace 40 is kept constant in the range of 450 ° C. or higher and 650 ° C. or lower, preferably 540 ° C. or higher and 600 ° C. or lower.
  • the temperature of the entire heating chamber is kept uniform.
  • the coated wire 2 that has passed through the heating furnace 40 is cooled by air at room temperature of 5 ° C. to 35 ° C.
  • the covered wire 2 is gradually and uniformly cooled, and the diffusion of zinc stops.
  • the heating furnace 40 has an inlet 46 and an outlet 48 for passing the covered wire 2.
  • a gap inevitably exists at the inlet 46 and the outlet 48, and air at normal temperature flows into the heating furnace 40 through the gap.
  • the heating furnace 40 is provided with a supply port 42, and nitrogen gas 44 is supplied into the heating furnace 40 from the supply port 42. The supply of the nitrogen gas 44 expels the air in the heating furnace 40 from the gap between the inlet 46 and the outlet 48. As a result, oxidation of the covered wire 2 and the heater 4 is prevented.
  • an apparatus for directly and locally heating a covered wire is provided close to the covered wire.
  • the coated wire is stopped in a heating furnace and heated for a predetermined time. This method is suitable when a long-time heat treatment is required, but a diffusion layer having a plurality of phases having different crystal structures is formed.
  • the heat treatment wire is passed through a die, and a wire electrode having a desired diameter is generated.
  • the spreadability of the ⁇ phase diffusion layer is lower than that of the ⁇ phase diffusion layer.
  • the heat treatment wire having a thickness of ⁇ 0.7 mm or more and ⁇ 1.2 mm or less including the ⁇ -phase diffusion layer having a thickness of 40 ⁇ m or more and 80 ⁇ m or less was reduced in diameter without destroying the diffusion layer.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Electrochemistry (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Mechanical Engineering (AREA)
  • Electrical Discharge Machining, Electrochemical Machining, And Combined Machining (AREA)
PCT/JP2013/071604 2012-08-09 2013-08-09 ワイヤ放電加工に用いるワイヤ電極 Ceased WO2014025007A1 (ja)

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
JP2012-177291 2012-08-09
JP2012177291 2012-08-09
JP2013047441A JP2014050945A (ja) 2012-08-09 2013-03-11 ワイヤ電極
JP2013-047441 2013-03-11

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WO2014025007A1 true WO2014025007A1 (ja) 2014-02-13

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JP (1) JP2014050945A (enExample)
TW (1) TWI618590B (enExample)
WO (1) WO2014025007A1 (enExample)

Families Citing this family (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN104191056B (zh) 2014-08-13 2016-06-29 宁波博威麦特莱科技有限公司 一种高精度锌基合金电极丝及其制备方法
TWI595951B (zh) * 2015-04-16 2017-08-21 Discharge processing electrode line
CN110125499B (zh) * 2019-05-14 2020-12-08 宁波博德高科股份有限公司 表层含碳的慢走丝电火花加工用电极丝及其制备方法

Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH01127228A (ja) * 1987-10-23 1989-05-19 Berkenhoff Gmbh 放電加工電極の製造法および放電加工電極
JPH03138341A (ja) * 1988-03-26 1991-06-12 Berkenhoff Gmbh 放電切断するためのワイヤ電極を製造する方法
JPH05192821A (ja) * 1991-08-02 1993-08-03 Trefimetaux 放電加工用電極及びその製造方法
JPH08318434A (ja) * 1995-03-24 1996-12-03 Berkenhoff Gmbh ワイヤー電極の製造方法並びにワイヤー電極
JPH09225748A (ja) * 1996-02-27 1997-09-02 Hitachi Cable Ltd 放電加工用電極線の製造方法
JP2002126950A (ja) * 2000-10-23 2002-05-08 Sumitomo Metal Mining Co Ltd ワイヤ放電加工用電極線の製造方法

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH01127228A (ja) * 1987-10-23 1989-05-19 Berkenhoff Gmbh 放電加工電極の製造法および放電加工電極
JPH03138341A (ja) * 1988-03-26 1991-06-12 Berkenhoff Gmbh 放電切断するためのワイヤ電極を製造する方法
JPH05192821A (ja) * 1991-08-02 1993-08-03 Trefimetaux 放電加工用電極及びその製造方法
JPH08318434A (ja) * 1995-03-24 1996-12-03 Berkenhoff Gmbh ワイヤー電極の製造方法並びにワイヤー電極
JPH09225748A (ja) * 1996-02-27 1997-09-02 Hitachi Cable Ltd 放電加工用電極線の製造方法
JP2002126950A (ja) * 2000-10-23 2002-05-08 Sumitomo Metal Mining Co Ltd ワイヤ放電加工用電極線の製造方法

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TW201408407A (zh) 2014-03-01
TWI618590B (zh) 2018-03-21
JP2014050945A (ja) 2014-03-20

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