WO2018145549A1 - 双单向电火花线切割方法 - Google Patents

双单向电火花线切割方法 Download PDF

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Publication number
WO2018145549A1
WO2018145549A1 PCT/CN2018/071867 CN2018071867W WO2018145549A1 WO 2018145549 A1 WO2018145549 A1 WO 2018145549A1 CN 2018071867 W CN2018071867 W CN 2018071867W WO 2018145549 A1 WO2018145549 A1 WO 2018145549A1
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wire
cutting method
discharge cutting
electric discharge
reverse
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PCT/CN2018/071867
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English (en)
French (fr)
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何赐文
赵晋胜
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何赐文
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Priority to JP2019542773A priority Critical patent/JP6872029B2/ja
Priority to US16/343,514 priority patent/US20200331083A9/en
Publication of WO2018145549A1 publication Critical patent/WO2018145549A1/zh

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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
    • B23H7/10—Supporting, winding or electrical connection of wire-electrode
    • 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

Definitions

  • the present application belongs to the technical field of wire electric discharge cutting, and particularly relates to a double unidirectional electric discharge wire cutting method.
  • EDM is the use of pulse spark discharge to remove the material to be processed, and there is no contact between the processing electrode and the material to be processed. Therefore, a soft electrode (tool) can be used to process a hard and brittle metal conductor. And semiconductor materials.
  • the moving wire electrode cutting process is the most extensive.
  • wire electrode cutting There are two types of wire electrode cutting: one-way wire (slow wire) and reciprocating wire (fast wire).
  • reciprocating wire cutting is a mechatronics technology with independent intellectual property rights developed by China. It is unique to China. The advantage is that the equipment is inexpensive, and the molybdenum alloy wire electrode (molybdenum wire) can be repeatedly used for repeated discharge.
  • the wire wire (usually copper wire) which has been cut by one-way wire (slow wire) is one-pass type, and the wire is led to the processing area by the wire barrel and discharged from the processing area after being discharged.
  • the electrode wire is seriously wasted; the wire electrode which is cut by the reciprocating wire (fast wire) is repeatedly used repeatedly, but the discharge is cut in both directions of the reciprocating wire, and the monofilament tube structure Limiting the length of the wire (generally only 200 to 300 meters) causes about 20 seconds to reversing to form frequent commutation stripes, and the processing accuracy is far worse than the one-way wire cutting.
  • Chinese Patent Publication No. CN105562854A discloses a unidirectional wire electric discharge cutting method for recycling a wire, comprising a forward wire step and a reverse wire step, a wire running direction of the forward wire step and a reverse wire step
  • the direction of the wire is reversed, and the discharge cutting process is performed when the wire is being drilled in the forward wire step, and the discharge cutting process is suspended when the wire is taken in the reverse wire step, and the speed of the reverse wire is greater than the speed of the forward wire.
  • the speed to the wire is 10 to 20 times the forward wire speed.
  • This method produces a commutation waiting time of about 10% because the reverse high-speed wire is not subjected to electrical discharge machining.
  • the present invention provides a double unidirectional wire electric discharge cutting method for overcoming the technical problems existing in the prior art, which can improve the processing efficiency and recycle the electrode wire while ensuring the processing precision.
  • a double unidirectional electric wire cutting method comprises a forward wire step and a reverse wire step, wherein the wire running direction of the forward wire step is opposite to the wire running direction of the reverse wire step, and the wire is being forward
  • the discharge cutting process completes one processing element
  • the wire cutting process completes another processing element when the wire is drilled in the reverse wire step.
  • the discharge is cut by both the forward wire step and the reverse wire step, and the direction is reversed after the cutting is completed. It can ensure that the commutation of the wire is not generated during the cutting process of a single machining element, and naturally no commutation fringe is generated, thereby improving the machining precision.
  • the two-way wire (fast wire) in the prior art can make the electrode wire recycle and the processing speed is fast, which is beneficial to reduce the processing cost.
  • a preferred technical solution is characterized in that the wire has a diameter of 0.12-0.18 mm.
  • the electrode wire of the above diameter has a strong ability to withstand current, which is advantageous for ensuring continuous processing capability.
  • a further preferred technical solution is characterized in that the electrode wire is a high temperature alloy wire.
  • high-temperature alloy wire is beneficial to improve the long-term processing ability of the electrode wire. Even if the large processing surface is processed, the processing precision and surface finish will not be affected by the problem of the wire itself.
  • high-temperature alloy wire tungsten-molybdenum alloy wire or molybdenum alloy wire can be used.
  • a preferred technical solution is characterized in that one machining element is one machining surface or a plurality of machining surfaces of one workpiece.
  • a preferred technical solution is characterized in that the power source used in the discharge cutting process is a pulse power source, and the frequency of the pulse power source is 0.032-8 MHz.
  • a preferred technical solution is characterized in that the wire feed speed in the forward wire running step is 0.5 to 12 m/s.
  • the method can be applied not only to the original application of the fast wire, but also to the case of slow wire walking.
  • a preferred technical solution is characterized in that the wire feed speed in the reverse wire running step is 0.5 to 12 m/s.
  • the method can be applied not only to the original application of the fast wire, but also to the case of slow wire walking.
  • a preferred technical solution is characterized in that: a double-wire reciprocating variable speed conveying mechanism is adopted, and the length of the wire which can be wound on each of the running cylinders is more than 5,000 meters.
  • the length of the wire By setting the length of the wire to be more than 5,000 meters, it is possible to apply to most of the wire-cut processing of a single machined surface, thereby ensuring that there is no need to replace the wire during the processing of one machined surface.
  • a further preferred technical solution is characterized in that a constant tension wire is used in the discharge cutting process.
  • the method of constant tension wire-feeding is beneficial to keep the speed of the wire receiving motor stable, thereby improving the machining accuracy.
  • a further preferred technical solution is characterized in that the power source used for the discharge cutting process is a pulse power source, and the frequency of the pulse power source is 0.032 to 8 MHz, and the wire cutting liquid used is a water-soluble wire cutting liquid matched with the pulse power source.
  • the water-soluble wire cutting liquid is used as the discharge medium, and it is not discharged (or rarely discharged) for a long time, is non-pollution to the working environment and nature, is non-toxic, harmless, and has no irritation to the human body.
  • FIG. 1 is a schematic view showing the structure of a double-cylinder variable-speed reciprocating wire transporting system used in Embodiment 1 of the present invention.
  • a double unidirectional electric wire cutting method comprises a forward wire step and a reverse wire step, wherein the wire running direction of the forward wire step is opposite to the wire running direction of the reverse wire step, and the wire is being forward
  • the discharge cutting process completes one processing element
  • the wire cutting process completes another processing element when the wire is drilled in the reverse wire step.
  • the discharge is cut by both the forward wire step and the reverse wire step, and the direction is reversed after the cutting is completed. It can ensure that the commutation of the wire is not generated during the cutting process of a single machining element, and naturally no commutation fringe is generated, thereby improving the machining precision.
  • the two-way wire (fast wire) in the prior art can make the electrode wire recycle and the processing speed is fast, which is beneficial to reduce the processing cost.
  • the wire has a diameter of from 0.12 to 0.18 mm.
  • the electrode wire of the above diameter has a strong ability to withstand current, which is advantageous for ensuring continuous processing capability.
  • the electrode wire is a high temperature alloy wire.
  • high-temperature alloy wire is beneficial to improve the long-term processing ability of the electrode wire. Even if the large processing surface is processed, the processing precision and surface finish will not be affected by the problem of the wire itself.
  • high-temperature alloy wire tungsten-molybdenum alloy wire or molybdenum alloy wire can be used.
  • one machining element is one machining surface or a plurality of machining surfaces of one workpiece.
  • the power source used in the discharge cutting process is a pulse power source, and the frequency of the pulse power source is 0.032 to 8 MHz.
  • the wire feed speed in the forward wire running step is 0.5 to 12 m/s.
  • the method can be applied not only to the original application of the fast wire, but also to the case of slow wire walking.
  • the wire feed speed in the reverse wire running step is 0.5 to 12 m/s.
  • the method can be applied not only to the original application of the fast wire, but also to the case of slow wire walking.
  • the double-wire barrel reciprocating variable speed wire feeding mechanism is adopted, and the length of the wire which can be wound on each wire barrel is more than 5000 meters.
  • the length of the wire By setting the length of the wire to be more than 5,000 meters, it is possible to apply to most of the wire-cut processing of a single machined surface, thereby ensuring that there is no need to replace the wire during the processing of one machined surface.
  • constant tension wire is used.
  • the method of constant tension wire-feeding is beneficial to keep the speed of the wire receiving motor stable, thereby improving the machining accuracy.
  • the power source used for the discharge cutting process is a pulse power source, and the frequency of the pulse power source is 0.032 to 8 MHz, and the wire cutting liquid used is a water-soluble wire cutting liquid matched with the pulse power source.
  • the water-soluble wire cutting liquid is used as the discharge medium, and it is not discharged (or rarely discharged) for a long time, is non-pollution to the working environment and nature, is non-toxic, harmless, and has no irritation to the human body.
  • a high-frequency nanosecond pulse power supply with a frequency of 4 MHz, an 8-column wire retainer, and a double-cylinder variable-speed reciprocating wire are installed.
  • the system performs wire cutting in the water-soluble discharge composition described in Chinese Patent Document CN101161797B, cutting Cr12 die steel, the workpiece thickness is 40 mm, the electrode adopts a molybdenum wire of 0.18 mm diameter, and the forward wire speed is 1 m/s, and the reverse direction is taken.
  • the wire speed was 1 m/s, and a square cylinder of 10 ⁇ 10 mm was cut and processed.
  • the surface roughness is Ra: 0.008-0.009mm, and there is no commutating stripe on the machined surface.
  • the surface quality of the one-time cutting process has reached the effect of cutting and repairing the “medium wire” machine tool three times and repeating the cutting.
  • the double-cylinder variable speed reciprocating wire system includes a forward wire barrel 1 and a reverse wire barrel 4, and the forward wire barrel 1 and the reverse wire barrel 4 are driven by a variable speed winding motor 2, respectively.
  • the connection, the forward wire barrel 1 and the reverse wire barrel 4 are used to pull a wire electrode 6.
  • the wire 6 By drawing the wire 6 in two directions by using the forward wire barrel 1 and the reverse wire barrel 4, respectively, on each of the wire barrels, there is only one area for receiving or releasing the wire 6 at the same time.
  • the electrode wire 6 is wound in a plurality of layers without being tangled, so that the number of the electrode wires 6 stored on the wire barrel can be remarkably increased. Thereby, it is possible to perform continuous cutting using the same electrode wire 6 for a single cutting element, and cutting with another wire cutting direction when cutting another cutting element.
  • variable speed winding motor 2 is a servo motor.
  • the servo motor drive is accurate and can be applied when the electrode wire 6 is wound and the winding diameter changes, thereby ensuring the wire running speed of the wire 6 is stable and improving the machining precision.
  • a godet wheel is disposed between the forward wire barrel 1 and the reverse wire barrel 4.
  • the position and direction of the electrode wire 6 in and out of the cutting area can be stabilized, so as to reduce the motor system jitter during the wire running process, thereby improving the machining precision.
  • the arrangement of the godet wheel and the arrangement of the forward wire barrel 1 and the reverse wire barrel 4 are such that the electrode wires 6 located between the forward wire barrel 1 and the reverse wire barrel 4 are in the same plane.
  • four guide rollers can be provided, wherein the first god guide wheel is disposed at the lay-up position of the forward wire barrel 1, and the second guide wire wheel and the third guide wire wheel can be vertical in the figure.
  • the fourth godet can be disposed at the take-up position of the reverse wire barrel 4. The four godets are in the same plane.
  • the forward wire barrel 1 is rotatably mounted on the first carriage 3, and the first carriage 3 is mounted with a variable speed winding motor 2 connected to the forward wire barrel 1, and the reverse wire barrel 4 is rotatably mounted.
  • the second carriage 5 is also mounted with a variable speed winding motor 2 connected to the reverse wire barrel 4, and the first carriage 3 and the second carriage 5 are respectively associated with the respective carriages.
  • the drive unit is driven and connected to the base 12 via a linear guide.
  • the rotation speeds of the two variable speed winding motors 2 of the wire barrel are different, so that each of the carriages for installing the wire barrel can be driven separately, so that the wire on each of the carriages can be made.
  • the tapping point and the threading point of the cylinder are precisely matched with the running plane of the electrode wire 6, thereby ensuring the stability of the length and tightness of the electrode wire 6, so as to improve the processing precision.
  • first carriage 3 and the second carriage 5 are respectively coupled to the carriage drive motor by a ball screw mechanism.
  • the ball screw mechanism has high transmission precision, and can accurately control the axial position of the carriage movement, which is beneficial to reducing the length variation of the wire 6 during the wire feeding process.
  • the carriage drive motor is a servo motor.
  • the servo motor is precise in transmission and can accurately control the axial position of the carriage movement, which is beneficial to reduce the length variation of the wire 6 during the wire feeding process.
  • one of the forward wire barrel 1 and the reverse wire barrel 4 is used for constant torque discharge, and the other is for constant speed winding.
  • the running speed of the wire 6 can be stabilized, and by constant torque discharging, a relatively stable load torque can be provided for the wire, thereby ensuring the stability of the wire winding speed.
  • the positive wire barrel 1 and the reverse wire barrel 4 are each wound with a wire 6 on a precision layer.
  • precision layer winding refers to winding.
  • the strip or wire on the wheel or barrel is closely spaced at the same level, so the outer layer of wire and strip can be considered to be wound around the inner layer of tape or wire. There is no confusion between the layers of the strip or the wire. So the expression is clear.
  • the difference between this embodiment and the embodiment 1 is that the Cr12 mold steel is cut, the workpiece thickness is 60 mm, the electrode is made of 0.18 mm diameter molybdenum wire, the forward wire speed is 4 m/s, and the reverse wire speed is 4 m/s, cutting.
  • a square cylinder of 10 x 10 mm is machined. There is no commutating stripe on the machined surface, and the surface quality of one-time cutting process has reached the effect of cutting and repairing the “medium wire” machine tool and repeating the cutting process twice.
  • the difference between this embodiment and the second embodiment is that the forward wire feed speed is 11 m/s, the reverse wire feed speed is 11 m/s, and the square cylinder of 10 ⁇ 10 mm is cut and processed. There is no commutating stripe on the machined surface, and the surface roughness can reach Ra value of 0.9 ⁇ m.
  • the precision of one-time cutting processing is one grade higher than that of the existing reciprocating wire (fast wire).

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  • Chemical Kinetics & Catalysis (AREA)
  • Electrochemistry (AREA)
  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
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Abstract

一种双单向电火花线切割方法，包括正向走丝步骤和反向走丝步骤，正向走丝步骤的走丝方向与反向走丝步骤的走丝方向相反，在正向走丝步骤中走丝时进行放电切割加工完成一个加工要素，在反向走丝步骤中走丝时放电切割加工完成另一个加工要素。该方法可以在保证加工精度的同时提高加工效率并使电极丝循环利用。

Description

双单向电火花线切割方法 技术领域
本申请属于电火花线切割工艺技术领域，特别是涉及一种双单向电火花线切割方法。
背景技术
电火花加工是利用脉冲火花放电蚀除被加工材料来进行加工，加工电极与被加工材料之间因存在液态电介质并不接触，所以可用较软的电极(工具)加工硬而脆的金属等导体和半导体材料。电火花加工中以移动的线电极切割加工最为广泛。线电极切割有单向走丝(慢走丝)和往复走丝(快走丝)两大类型，其中往复走丝线切割是我国自主发展的具有完全知识产权的机电一体化技术，为我国所特有，其优点是设备造价低廉，钼合金线电极(钼丝)可多次反复放电使用。特别适合机械加工难以胜任的高硬度、高强度、高熔点、高韧性、高脆性材料(如：钨钼合金、记忆合金、镁合金、硬质合金、聚晶金刚石、钕铁硼等)的加工，广泛应用于模具制做、航天航空、医疗器械、仪器仪表、电子电器、机械制造等各领域的精密或异型零部件的加工、制造。
目前已有单向走丝(慢走丝)线切割的电极丝(一般是铜丝)都是一次通过式使用，电极丝由储丝筒引送至加工区一次放电后离开加工区就报废了，尤其是小能量切割时造成电极丝的严重浪费；往复走丝(快走丝)线切割的电极丝是多次反复使用，但因往复走丝的两个方向都放电切割，且单丝筒结构限制了电极丝的长度(一般只有200～300米)造成20秒左右就换向形成频繁换向条纹，加工的精度远远差于单向走丝线切割。
中国专利文献CN105562854A公开了一种循环使用电极丝的单向电火花线切割方法，包括正向走丝步骤和反向走丝步骤，正向走丝步骤的走丝方向与反向走丝步骤的走丝方向相反，在正向走丝步骤中走丝时进行放电切割加工，在反向走丝步骤中走丝时暂停放电切割加工，反向走丝的速度大于正向走丝的速度，反向走丝的速度是正向走丝速度的10～20倍。该方法由于反向高速走丝是不进行放电加工，因而产生了10％左右的换向等待时间。
发明内容
本发明为克服现有技术中存在的技术问题而提供双单向电火花线切割方法，该方法可以在保证加工精度的同时提高加工效率并使电极丝循环利用。
一种双单向电火花线切割方法，包括正向走丝步骤和反向走丝步骤，正向走丝步骤的走丝方向与反向走丝步骤的走丝方向相反，在正向走丝步骤中走丝时进行放电切割加工完成一个加工要素，在反向走丝步骤中走丝时放电切割加工完成另一个加工要素。
通过在正向走丝步骤和反向走丝步骤中均放电切割，并且在切割完成一个加工要素之后再换向。可以保证对于单一加工要素的切割过程中不会产生电极丝的换向，自然也不会产生换向条纹，从而提高了加工精度。同时也具备了现有技术中的双向走丝(快走丝)可以使电极丝循环利用和加工速度快的优点，有利于降低加工成本。
优选的技术方案，其附加技术特征在于：电极丝的直径为0.12-0.18mm。
采用上述直径的电极丝，承受电流的能力强，有利于保证持续加工能力。
进一步优选的技术方案，其附加技术特征在于：电极丝为高温合金丝。
选用高温合金丝，有利于提高电极丝的持久加工能力，即使加工较大的加工面，也不会因为电极丝本身的问题而影响加工精度和表面光洁度。高温合金丝，可以选用钨钼合金丝或钼合金丝。
优选的技术方案，其附加技术特征在于：一个加工要素为一个工件的一个加工面或多个加工面。
当工件较小的时候，也可以选择采用某一走丝方向加工多个加工面甚至全部的加工面，从而有利于提高电极丝在全长度范围内的使用的均匀性，减少电极丝局部使用过于频繁消耗较快而其他部位使用频率较低消耗较慢的问题，从而提高电极丝的使用寿命。
优选的技术方案，其附加技术特征在于：放电切割加工所使用的电源为脉冲电源，脉冲电源的频率为0.032-8MHz。
优选的技术方案，其附加技术特征在于：正向走丝步骤中的走丝速度为0.5～12m/s。
本方法不但可以适用于原适用快走丝的场合，还可以适用于慢走丝的场合。
优选的技术方案，其附加技术特征在于：反向走丝步骤中的走丝速度为0.5～12m/s。
本方法不但可以适用于原适用快走丝的场合，还可以适用于慢走丝的场合。
优选的技术方案，其附加技术特征在于：采用双走丝筒往复可变速运丝机构，每个走丝筒上能够缠绕的电极丝长度为5000米以上。
通过将电极丝的长度设定为5000米以上，可以适用绝大多数线切割加工加工单加工面的情况，从而能够保证对一个加工面的加工过程中，无需更换电极丝。
进一步优选的技术方案，其附加技术特征在于：在放电切割加工时，采用恒张力走丝。
采用恒张力走丝的方式，有利于收丝的电机速度保持稳定，从而提高加工精度。
更进一步优选的技术方案，其附加技术特征在于：放电切割加工所使用的电源为脉冲电源，脉冲电源的频率为0.032～8MHz，使用的线切割液为与脉冲电源匹配的水溶性线切割液。
使用水溶性线切割液作为放电介质，长期使用不排放(或极少排放)、对工作环境和大自然无污染、无毒、无害，并对人体无刺激。
附图说明
图1是本发明实施例1中所使用的双丝筒可变速往复运丝系统的结构示意图。
具体实施方式
为能进一步了解本发明的发明内容、特点及功效，兹例举以下实施例，并详细说明如下：
实施例1：
一种双单向电火花线切割方法，包括正向走丝步骤和反向走丝步骤，正向走丝步骤的走丝方向与反向走丝步骤的走丝方向相反，在正向走丝步骤中走丝时进行放电切割加工完成一个加工要素，在反向走丝步骤中走丝时放电切割加工完成另一个加工要素。
通过在正向走丝步骤和反向走丝步骤中均放电切割，并且在切割完成一个加工要素之后再换向。可以保证对于单一加工要素的切割过程中不会产生电极丝的换向，自然也不会产生换向条纹，从而提高了加工精度。同时也具备了现有技术中的双向走丝(快走丝)可以使电极丝循环利用和加工速度快的优点，有利于降低加工成本。
优选的，电极丝的直径为0.12-0.18mm。
采用上述直径的电极丝，承受电流的能力强，有利于保证持续加工能力。
进一步优选的，电极丝为高温合金丝。
选用高温合金丝，有利于提高电极丝的持久加工能力，即使加工较大的加工面，也不会因为电极丝本身的问题而影响加工精度和表面光洁度。高温合金丝，可以选用钨钼合金丝或钼合金丝。
优选的，一个加工要素为一个工件的一个加工面或多个加工面。
当工件较小的时候，也可以选择采用某一走丝方向加工多个加工面甚至全部的加工面，从而有利于提高电极丝在全长度范围内的使用的均匀性，减少电极丝局部使用过于频繁消耗较快而其他部位使用频率较低消耗较慢的问题，从而提高电极丝的使用寿命。
优选的，放电切割加工所使用的电源为脉冲电源，脉冲电源的频率为0.032～8MHz。
优选的，正向走丝步骤中的走丝速度为0.5～12m/s。
本方法不但可以适用于原适用快走丝的场合，还可以适用于慢走丝的场合。
优选的，反向走丝步骤中的走丝速度为0.5～12m/s。
本方法不但可以适用于原适用快走丝的场合，还可以适用于慢走丝的场合。
优选的，采用双走丝筒往复可变速运丝机构，每个走丝筒上能够缠绕的电极丝长度为5000米以上。
通过将电极丝的长度设定为5000米以上，可以适用绝大多数线切割加工加工单加工面的情况，从而能够保证对一个加工面的加工过程中，无需更换电极丝。
进一步优选的，在放电切割加工时，采用恒张力走丝。
采用恒张力走丝的方式，有利于收丝的电机速度保持稳定，从而提高加工精度。
更进一步优选的，放电切割加工所使用的电源为脉冲电源，脉冲电源的频率为0.032～8MHz，使用的线切割液为与脉冲电源匹配的水溶性线切割液。
使用水溶性线切割液作为放电介质，长期使用不排放(或极少排放)、对工作环境和大自然无污染、无毒、无害，并对人体无刺激。
具体说来，是在已有快走丝线切割机床的基础上，采用频率为4MHz的高频纳秒脉冲电源、加装8柱型电极丝保持器后，并且加装双丝筒可变速往复运丝系统，在中国专利文献CN101161797B所述的水溶性放电组合物中进行线切割，切割Cr12模具钢、工件厚度40mm，电极采用0.18毫米直径的钼丝，正向走丝速度1m/s，反向走丝速度1m/s，切割加工10×10mm的四方柱体。表面粗糙度为Ra：0.008～0.009mm，加工表面无换向条纹，一次切割加工的表面质量达到了“中走丝”机床切一修二，三次重复切修的效果。
具体的，双丝筒可变速往复运丝系统包括正向走丝筒1和反向走丝筒4，正向走丝筒1和反向走丝筒4分别与一台变速卷绕电机2驱动连接，正向走丝筒1和反向走丝筒4用于牵引一根电极丝6。
通过在分别利用正向走丝筒1和反向走丝筒4对电极丝6进行两向的牵引，在每个走丝筒上，同时只存在一处接受或释放电极丝6的区域，可以多层缠绕电极丝6而不会乱丝，所以可以显著的增加走丝筒上储存的电极丝6的数量。从而能够实现对单一切割要素的连续使用同一根电极丝6进行切割，在对另一切割要素进行切割时采用另一走丝方向进行切割。
优选的，变速卷绕电机2为伺服电机。
伺服电机传动精确，可以适用在电极丝6层绕、卷径发生变化的时候，从而保证电极丝6的走丝速度稳定，提高了加工精度。
优选的，正向走丝筒1和反向走丝筒4之间设有导丝轮。
通过导丝轮，可以稳定电极丝6的进出切割区域的位置和方向，以降低走丝过程中的电机系抖动，从而提高了加工精度。
进一步优选的，导丝轮的设置和正向走丝筒1、反向走丝筒4的设置使得位于正向走丝筒1和反向走丝筒4之间的电极丝6处于同一平面内。具体说来，可以设置4个导丝轮，其中第一导丝轮设置在正向走丝筒1的放丝位置处，第二导丝轮和第三导丝轮可以以图中的竖直方向设置，第四导丝轮可以设置在反向走丝筒4的收丝位置处。4个导丝轮位于同一平面内。
通过将导丝轮设置在同一平面内，可以尽量减少走丝过程中的电极丝6的扭转，以延长电极丝6的使用寿命。
优选的，正向走丝筒1转动安装在第一拖板3上，第一拖板3上安装有与正向走丝筒1连接的变速卷绕电机2，反向走丝筒4转动安装在第二拖板5上，第二拖板5上也安装有与反向走丝筒4连接的变速卷绕电机2，第一拖板3和第二拖板5分别地与各自的拖板驱动装置传动连接，并通过直线导轨连接在底座12上。
由于各个走丝筒的即时卷径不同，所以两个走丝筒的变速卷绕电机2的转速不同，所以单独驱动每个安装走丝筒的拖板，可以使得每个拖板上的走丝筒的出丝点和入丝点精确的与电极丝6的运行平面匹配，从而保证了电极丝6的长度和松紧程度的稳定性，以利于提高加工精度。
进一步优选的，第一拖板3和第二拖板5分别通过滚珠丝杠机构与拖板驱动电机连接。
滚珠丝杠机构传动精度高，可以精确的控制拖板移动的轴向位置，有利于减少电极丝6在走丝过程中的长度变化。
再进一步优选的，拖板驱动电机为伺服电机。
伺服电机传动精确，可以精确的控制拖板移动的轴向位置，有利于减少电极丝6在走丝过程中的长度变化。
优选的，正向走丝筒1和反向走丝筒4中，其中一个用于恒扭矩放丝，其中另一个用于恒转速收丝。
通过恒转速收丝，可以稳定电极丝6的运行速度，而通过恒转矩放丝，可以为收丝 提供一个较为稳定的负载力矩，从而保证了收丝速度的稳定。
优选的，正向走丝筒1和反向走丝筒4上均精密层绕有电极丝6。需要说明的是，“精密层绕”中的“精密”二字，不应做通常的“高”“矮”“薄”“厚”的形容词来理解，精密层绕，指的是在卷绕在轮或筒上的带材或线材，在同一层高度上，是紧密的布置的，所以更外面一层的线材和带材可以认为是缠绕在内层的带材或线材上的。各层带材或线材之间不会产生混乱的情况。所以该表达是清楚的。
通过精密层绕的方式，可以利用已经收卷的电极丝6或尚未放卷的电极丝6来保证收丝点或放丝点的即时卷径的可靠，从而保证了放丝和收丝速度的精确可靠。
实施例2：
本实施例与实施例1的不同之处在于，切割Cr12模具钢、工件厚度60mm，电极采用0.18毫米直径的钼丝，正向走丝速度4m/s，反向走丝速度4m/s，切割加工10×10mm的四方柱体。加工表面无换向条纹，一次切割加工的表面质量达到了“中走丝”机床切一修一，二次重复切修的效果。
实施例3：
本实施例与实施例2的不同之处在于，正向走丝速度11m/s，反向走丝速度11m/s，切割加工10×10mm的四方柱体。加工表面无换向条纹，表面粗糙度可以达到Ra值为0.9μm，一次切割加工的精度比已有的往复走丝(快走丝)线切割高一个等级。
尽管上面结合附图对本发明的优选实施例进行了描述，但是本发明并不局限于上述的具体实施方式，上述的具体实施方式仅仅是示意性的，并不是限制性的，本领域的普通技术人员在本发明的启示下，在不脱离本发明宗旨和权利要求所保护的范围情况下，还可以作出很多形式。这些均属于本发明的保护范围之内。

Claims (10)

  1. 一种双单向电火花线切割方法，其特征在于：包括正向走丝步骤和反向走丝步骤，所述正向走丝步骤的走丝方向与所述反向走丝步骤的走丝方向相反，在所述正向走丝步骤中走丝时进行放电切割加工完成一个加工要素，在所述反向走丝步骤中走丝时放电切割加工完成另一个加工要素。
  2. 根据权利要求1所述的双单向电火花线切割方法，其特征在于：使用的电极丝的直径为0.12～0.18mm。
  3. 根据权利要求2所述的双单向电火花线切割方法，其特征在于：所述电极丝为高温合金丝。
  4. 根据权利要求1所述的双单向电火花线切割方法，其特征在于：所述一个加工要素为一个工件的一个加工面或多个加工面。
  5. 根据权利要求1所述的双单向电火花线切割方法，其特征在于：放电切割加工所使用的电源为脉冲电源，所述脉冲电源的频率为0.032～8MHz。
  6. 根据权利要求1所述的双单向电火花线切割方法，其特征在于：所述正向走丝步骤中的走丝速度为0.5～12m/s。
  7. 根据权利要求1所述的双单向电火花线切割方法，其特征在于：所述反向走丝步骤中的走丝速度为0.5～12m/s。
  8. 根据权利要求1所述的双单向电火花线切割方法，其特征在于：采用双走丝筒往复可变速运丝机构，每个走丝筒上能够缠绕的电极丝长度为5000米以上。
  9. 根据权利要求8所述的双单向电火花线切割方法，其特征在于：在放电切割加工时，采用恒张力走丝。
  10. 根据权利要求8或9所述的双单向电火花线切割方法，其特征在于：放电切割加工所使用的电源为脉冲电源，所述脉冲电源的频率为0.032～8MHz，使用的线切割液为与所述脉冲电源匹配的水溶性线切割液。
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