WO2019127614A1 - 一种高效冲洗电极丝及其制备方法 - Google Patents

一种高效冲洗电极丝及其制备方法 Download PDF

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Publication number
WO2019127614A1
WO2019127614A1 PCT/CN2018/000333 CN2018000333W WO2019127614A1 WO 2019127614 A1 WO2019127614 A1 WO 2019127614A1 CN 2018000333 W CN2018000333 W CN 2018000333W WO 2019127614 A1 WO2019127614 A1 WO 2019127614A1
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strip
electrode wire
core material
wire
shaped
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PCT/CN2018/000333
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English (en)
French (fr)
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梁志宁
万林辉
吴桐
林火根
孟宪旗
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宁波博德高科股份有限公司
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Publication of WO2019127614A1 publication Critical patent/WO2019127614A1/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
    • 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
    • B23H7/22—Electrodes specially adapted therefor or their manufacture
    • 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
    • B23H7/22—Electrodes specially adapted therefor or their manufacture
    • B23H7/24—Electrode material

Definitions

  • the invention relates to the field of electrode wires, in particular to a high-efficiency rinsing electrode wire and a preparation method thereof.
  • the liquid is taken away in time, which not only reduces the cutting efficiency, but also causes excessive heat loss on the wire, causing the wire to be blown due to overheating.
  • Ordinary electrode wire materials are particularly prone to breakage when cutting shaped high hardness alloys or high temperature resistant super alloy materials under the above complicated working conditions, and the cutting efficiency is low.
  • the first technical problem to be solved by the present invention is to provide a highly efficient rinsing electrode wire with high cutting efficiency for the prior art.
  • a second technical problem to be solved by the present invention is to provide a highly efficient rinsing electrode wire having a low breaking frequency for the prior art.
  • a third technical problem to be solved by the present invention is to provide a method for preparing the above-mentioned high-efficiency rinsing electrode wire which is simple in production process and strong in operability, in view of the prior art.
  • a high-efficiency rinsing electrode wire comprising a core material, wherein the surface of the core material has strip-like protrusions extending along a surface thereof Each strip-shaped protrusion is spaced apart, and the bottom edge of each strip-shaped protrusion is diffused into the core material to form a convex edge;
  • the mass percentage of copper in the core material is 58.5-67.5 wt%, and the balance is zinc And inevitable impurities, and the mass percentage content of the unavoidable impurities is 0.5 wt% or less;
  • the mass percentage of zinc in the strip-like protrusions is 57.8 to 69.8 wt%, and the balance is copper and unavoidable impurities, and the The mass percentage content of the unavoidable impurities is 0.3% by weight or less.
  • the core material having a copper content of 58.5 to 67.5 wt% has good tensile strength and sufficient plastic toughness. Because in the EDM process, the wire must be able to withstand a certain tension and impact caused by the discharge, if the material strength is too low or the fracture toughness is too low, the electrode wire will be shaken, and eventually the surface of the cutting workpiece is rough, It can even cause multiple cutting line marks, especially for metal workpieces that are difficult to process in a suspended state, such as high hardness materials and high temperature resistant super alloy materials.
  • the tension applied during cutting (the strength of the constituent electrode wire materials) is larger. The easier it is to cut, the better the plastic toughness, the less likely it is to break the wire.
  • the copper content is 61.5-64.5 wt%, and the copper content of 61.5-64.5 wt% also contributes to the straightness recovery of the electrode wire, contributes to threading, and the electrode wire material with good toughness is also beneficial for taper cutting. of.
  • the strip-shaped protrusions with a zinc content of 57.8 to 69.8 wt% have very good gasification performance and are particularly advantageous for improving cutting efficiency. Due to the relatively high zinc content in the strip-shaped protrusions, a large amount of vaporized zinc will bring the energy generated by the discharge in the cutting to the surface of the cut metal, and improve the flushing effect, and the gas pressure generated by the zinc gasification will also discharge.
  • the zinc content is 57.8 to 69.8 wt% and has a ⁇ phase structure. Since the ⁇ phase structure is hard and brittle, and the processing property is poor, the strip bulge can be increased by providing the convex edge. The bonding force with the core material can effectively prevent the powder falling due to the falling off of the protrusion.
  • the zinc content is 43.5 to 53.5 wt%, and the convex edge has a ⁇ phase structure, and the phase structure has good electrical conductivity, and can effectively transfer discharge energy, thereby improving discharge cutting efficiency.
  • the strip-like projections are spirally distributed on the surface of the core material. It is well known that the premise of stable cutting of wire EDM must first ensure that the wire is continuously cut during the cutting process, and the probability of wire breakage is mainly related to the heat dissipation performance, cooling state and chip discharge performance of the wire itself.
  • the strip-like convex structure provided by the invention can significantly increase the surface area of the wire, so that the heat lost by the wire itself is significantly increased per unit time, thereby avoiding excessive heat loss on the wire, causing the wire to burn due to overheating. Broken.
  • the working fluid When the workpiece is suspended above and below, the working fluid has insufficient flushing pressure, and the surface of the cut workpiece after cutting is covered with adhesive or even powdery etching products, which is mainly accompanied by high temperature above 10000 ° C in the discharge channel, working medium It is formed by decomposing a large amount of polymer compound and reacting with a metal etching product to form a colloidal or granular substance. These materials will adhere to the slit and accumulate mainly at the exit of the slit, which seriously affects the elimination of the electrolytic corrosion product and makes it difficult to enter the slit into the fresh working medium.
  • adhesive or even powdery etching products which is mainly accompanied by high temperature above 10000 ° C in the discharge channel, working medium It is formed by decomposing a large amount of polymer compound and reacting with a metal etching product to form a colloidal or granular substance.
  • the electrode wire provided by the wood invention can effectively inject more fresh working fluid with the movement of the wire wire discharge machining, especially the spiral convex structure, so that the workpiece and the wire surface are cooled in time to avoid surface burn of the workpiece or Damage to the wire, causing burnt in severe cases.
  • the spiral strip-shaped convex structure of the wire can store a large number of etching products, and reduce the adhesion of the processing chips to the surface of the electrode wire, thereby improving the chip discharging performance and reducing the probability of wire breakage. Because the adhesive acts to concentrate the discharge on the wire, if the cooling and heat dissipation conditions are poor, it is likely to raise the temperature at that place, so that in the continuous discharge, other processing chips may continue to adhere.
  • the spiral strip-like protrusions spiral around the surface of the core material, and have a good diversion effect and a self-rinsing effect on the working fluid from top to bottom, because the working fluid spirally falls along the surface of the electrode wire, so that the walking
  • the smooth liquid column formed during the wire process improves the self-rinsing ability, reduces the surface pressure of the wire, enhances the cooling capacity, prevents the wire from being blown due to excessive temperature, thereby improving the cutting safety factor and reducing the frequency of wire breakage.
  • the spiral strip-like protrusions allow the working fluid to flow in the tangential direction to avoid collision with the surface of the electrode wire, ensuring that the liquid rotates downwardly, forming a relatively dense rotating water flow, which greatly absorbs the generation of the wire electric discharge. A lot of heat to prevent broken wires.
  • high-pressure flushing is usually adopted because the speed of water flow is relatively fast and there is no mitigation, so it will cause a large energy loss during the cutting process, which is not conducive to improving the cutting efficiency.
  • the spiral strip-like protrusion not only makes the high-pressure flushing water flowing through the surface of the electrode wire not easy to block, but also makes the flushing speed more stable, avoids the discharge energy being lost too early, and is beneficial to improving the cutting efficiency.
  • the strip-like projections are continuously or discontinuously distributed on the surface of the core material along its length.
  • the strip-shaped protrusion has a cross section of one of a trapezoidal shape, a rectangular shape, a triangular shape or a zigzag shape.
  • the strip-shaped protrusions have a radial extension distance of 4 to 20 ⁇ m with respect to the surface of the core material.
  • an axial distance between one side of one of the convex segments and the same side of the other convex segment is 2 to 80 ⁇ m.
  • the adjacent convex segments of the strip-like protrusions form an angle of 0 to 60°.
  • the mass percentage of zinc in the convex edge is 43.5 to 53.5 wt%
  • the balance is copper and unavoidable impurities
  • the mass percentage of the unavoidable impurities is 0.12 wt% or less.
  • the zinc content is 43.5 to 53.5 wt%
  • the convex edge has a ⁇ phase structure, and the phase structure has good electrical conductivity and effectively transmits discharge energy, thereby improving discharge cutting efficiency.
  • the convex rim has a maximum dimension in the radial direction of 1.5 to 8 ⁇ m.
  • the raised edge enables the strip-shaped protrusion to be better combined with the core material, thereby further effectively preventing the powder falling due to the falling of the strip-shaped protrusion.
  • the technical solution adopted by the present invention to solve the above third technical problem is: a method for preparing a high-efficiency rinsing electrode wire as described above, characterized in that it comprises the following steps:
  • the diameter of the bus bar required for preparing the core material is 0.5 to 1.2 mm;
  • the bus bar is degreased-acid washed-washed-galvanized, and the thickness of the zinc plating layer is 3-15 ⁇ m, and the first wire blank is obtained, wherein the plating current is 1200-2500 A, and the voltage is 120-220 V:
  • the third wire blank obtained by the above method is subjected to rotary continuous drawing and retreating processing using a special-shaped die, the drawing speed is 800-1200 m/min, the annealing voltage is 12-60 V, and the annealing current is 15-50 A.
  • the invention has the advantages that: in the invention, the surface of the core material is convexly provided with strip-shaped protrusions, and each strip-shaped protrusion is spaced apart, so that the surface area of the electrode wire can be significantly increased, and the unit is obviously increased.
  • the heat lost by the wire itself during the time thereby avoiding the excessive loss of heat of the wire, causing the wire to be blown due to overheating.
  • the strip-shaped convex structure can effectively inject more fresh working fluid, so that the surface of the workpiece and the electrode wire is cooled in time to avoid surface burn or damage the electrode wire. In severe cases, it causes burning.
  • the strip-shaped convex structure can store a large amount of etching products, and reduce the adhesion of the processing chips to the surface of the electrode wire, thereby improving the chip discharging performance and reducing the probability of wire breakage.
  • the core material has a copper content of 58.5 to 67.5 wt%, so that the core material has good tensile strength and sufficient plastic toughness, so that the electrode wire of the invention has greater tension and better plastic toughness. Further, good cutting performance is obtained and it is not easy to break.
  • the zinc content of the strip-like protrusions is 57.8 to 69.8 wt%, so that the gasification performance of the electrode wire is better, which is favorable for improving the cutting efficiency.
  • the strip-shaped protrusions have a ⁇ -phase structure, so that by providing the raised edges, the bonding force of the strip-shaped protrusions and the core material can be increased, thereby effectively preventing the powder falling due to the falling off of the strip-shaped protrusions.
  • the electrode wire of the present invention has high cutting efficiency, and is particularly suitable for cutting processing of high-hardness alloys or high-temperature resistant materials with a top or bottom suspension or a certain taper.
  • the preparation method of the invention has the advantages of simple production process, strong operability, less preparation steps, simple production equipment, easy production of products meeting the requirements, and easy realization of large-scale and automatic production.
  • FIG. 1 is a schematic structural view of a wire electrode according to an embodiment of the present invention (a strip-shaped protrusion is continuously distributed);
  • FIG. 2 is a schematic structural view of a wire electrode according to an embodiment of the present invention (discontinuous distribution of strip-shaped protrusions);
  • Figure 3 is an enlarged view of a portion I of Figure 2;
  • FIG. 4 is a schematic view showing a process of preparing a wire electrode according to an embodiment of the present invention (discontinuous distribution of strip-shaped protrusions);
  • Figure 5 is a photomicrograph of a wire electrode (continuous distribution of strip-shaped protrusions) in an embodiment of the present invention
  • Figure 6 is a photomicrograph of a wire electrode (discontinuous distribution of strip-like projections) in an embodiment of the present invention.
  • the preparation process of the high-efficiency rinsing electrode wire in the present invention is as follows: the copper-zinc alloy required for preparing the core material is drawn into a bus bar having a diameter of 0.5 to 1.2 mm (as shown in FIG. 4-A), and the prepared bus bar is removed. Oil-acid washing-water washing-galvanizing treatment, zinc plating thickness is 3-15 ⁇ m, and the first strand blank is obtained (as shown in Fig. 4-B), wherein the plating current is 1200-2500 A, and the voltage is 120-220V.
  • the first wire blank obtained by the above is subjected to an alloying heat treatment at a temperature of 290 to 350 ° C and a heat treatment time of 3 to 8 hours, and a convex material is formed on the core material to obtain a second wire blank (as shown in Fig. 4-C). Show). Performing a contact in-line diffusion annealing treatment on the second wire blank prepared as described above, so that the convex edge material is formed between the core material and the protrusion to obtain a third wire blank (as shown in FIG. 4-D), wherein the processing The speed is 10-20 m/min, the annealing current is 25-100 A, and the voltage is 50-180V.
  • the third wire blank obtained by the above method is subjected to rotary continuous drawing and retreating processing with a special-shaped die, the drawing speed is 800-1200 m/min, the annealing voltage is 12-60 V, the annealing current is 15-50 A, and the diameter is 0.15.
  • ???0.30mm electrode wire finished product (as shown in Figure 4-E, Figure 4-E is the cross-sectional view of Figure 2), the photomicrograph shown in Figure 5 and Figure 6, the electrode wire finished core surface formation The above-mentioned strip-like projections.
  • the finished electrode wire is shown in Figures 1-3, and comprises a core material 1.
  • the surface of the core material 1 has strip-like protrusions 2 extending along the surface thereof, and the strip-like protrusions 2 are spaced apart and each strip The bottom edges of the projections 2 are all diffused into the core material 1 to form the raised edges 22.
  • the strip-like protrusions 2 are spirally distributed on the surface of the core material 1 and continuously distributed along the longitudinal direction thereof; as shown in FIG. 2, the strip-like protrusions are shown in FIG. 2 is discontinuously distributed along its length.
  • the cross section of the strip-shaped protrusion 2 is preferably trapezoidal.
  • the shape of the cross section of the strip-shaped protrusion 2 may be any one of a rectangular shape, a triangular shape or a zigzag shape.
  • the radial extension distance L of the strip-like projections 2 with respect to the core material surface 1 is 4 to 20 ⁇ m.
  • the strip-like projections 2 in the present invention are spirally distributed on the surface of the core material 1 and are continuous, and thus the number N of spirals of the strip-like projections 2 can be 1, 2, 3 or 4.
  • the number of spirals of the strip-shaped protrusions 2 is 1, and among the adjacent ones of the strip-shaped protrusions 2, one side of the one of the protrusions 21 and the other protrusion
  • the axial distance P of the same side of the segment 21 is 2 to 80 ⁇ m
  • the adjacent convex segment 21 of the strip-like projection 2 forms an angle ⁇ of 0 to 60°, and the convex edge 22 has the largest radial direction.
  • the size S is 1.5 to 8 ⁇ m.
  • the elemental composition of the electrode wire in the present invention is as follows: the mass percentage of copper in the core material is 58.5 to 67.5 wt%, the balance is zinc and unavoidable impurities, and the mass percentage of the unavoidable impurity is 0.5 wt or less. %.
  • the mass percentage of zinc in the strip-shaped protrusions is 57.8 to 69.8 wt%, the balance is copper and unavoidable impurities, and the mass percentage content of the unavoidable impurities is 0.3 wt% or less.
  • the mass percentage of zinc in the raised edge is 43.5 to 53.5 wt%, the balance is copper and unavoidable impurities, and the mass percentage of the unavoidable impurities is 0.12 wt% or less.
  • the above-mentioned preparation method is used to obtain a highly efficient rinsing electrode wire having the above elemental composition and structure.
  • the specific element content, strip-like convex features and properties are shown in Table 1, Table 2 and Table 3.
  • Comparative Example 1 A commercially available H62 brass wire having a diameter of 0.25 mm.
  • a galvanized electrode wire comprising a core material of H63 brass having a diameter of 0.9 to 1.2 mm, directly galvanized on the surface of the core material, having a plating thickness of 10 to 20 um, and then being subjected to continuous drawing and retreating to obtain a diameter of 0.25mm galvanized electrode wire.
  • the utility model relates to a high-speed electrode wire, which is composed of H60 brass with a diameter of 0.9-1.2 mm, and then galvanized on the surface of the core material, and the thickness of the plating layer is 10-30 um, to obtain a first strand blank, and heat-treating the first strand blank.
  • the temperature of the heat treatment process is 410 ° C
  • the time is 10 h
  • the second wire blank is obtained.
  • the second wire blank after heat treatment is subjected to continuous drawing and retreating to form a high-speed electrode wire having a diameter of 0.25 mm, and the surface layer structure is a ⁇ phase.
  • a high-speed electrode wire consisting of H63 brass with a diameter of 0.9-1.2 mm, and then galvanized on the surface of the core material, the thickness of the plating layer is 10-30 um, the first strand blank is obtained, and the first strand blank is heat-treated.
  • the temperature of the heat treatment process is 550 ° C, the time is 20 h, the second wire blank is obtained, and finally the second wire blank after the heat treatment is subjected to continuous drawing and retreating to form a high-speed electrode wire having a diameter of 0.25 mm, and the surface layer structure is a ⁇ phase.
  • Comparative Example 5-8 The preparation method was the same as in the examples. See Table 1, Table 2, and Table 3 for the specific element content, strip-like convex characteristics, and properties of the electrode wires of Comparative Examples 1-8.
  • the final formed electrode wires prepared in the above Examples 1 to 12 and Comparative Examples 1 to 8 were tested for physical properties (tensile strength and elongation) on a universal electronic tensile tester, and tested with a 718 nickel-based alloy as a material.
  • the broken filament frequency and cutting efficiency of the prepared finalized electrode wire are shown in Table 3.
  • the electrode wire of the present invention can effectively reduce the wire breakage rate and improve the cutting efficiency on the basis of ensuring the physical properties thereof compared with the electrode wire in the comparative example.

Abstract

一种高效冲洗电极丝，包括芯材（1），芯材（1）的表面具有沿其表面延伸的条状凸起（2），各条状凸起（2）间隔设置，且各条状凸起（2）的底缘均扩散至芯材（1）中而形成凸起边缘（22）；芯材（1）中铜的质量百分数含量为58.5～67.5wt％，余量为锌及不可避免杂质；条状凸起（2）中锌的质量百分数含量为57.8～69.8wt％，余量为铜及不可避免的杂质。高效冲洗电极丝切割效率高，生产工艺简单，易于实现规模化、自动化生产。还公开了一种高效冲洗电极丝的制备方法。

Description

一种高效冲洗电极丝及其制备方法 技术领域
本发明涉及电极丝领域，尤其涉及一种高效冲洗电极丝及其制备方法。
背景技术
近年来，随着中国制造业的快速发展，数控低速走丝电火花线切割加工因其优异的加工性能而被越来越广泛的应用。然而，普通电极丝在加工一些复杂、异型、悬空或高厚度工件时表现的并不理想，例如；航空涡轮发动机镍基合金，医学领域用制造人工植入物钛合金，重型装载成套装备专用高厚大型齿轮或汽车行业异型覆盖件冲模等。此类工件通常形状复杂、上下悬空、落差大、带有一定锥度，且为高硬度合金或耐高温材料等，从而导致工作液冲洗效果降低，电火花线切割时产生大量的热量且无法被工作液及时带走，这不仅会降低切割效率，而且会使过多的热量损耗在电极丝上，导致电极丝因过热而烧断。普通电极丝材料在以上这种复杂工况条件下切割异型高硬度合金或耐高温超级合金材料时特别容易断丝，且切割效率低。
发明内容
本发明所要解决的第一个技术问题是针对现有技术而提供一种切割效率高的高效冲洗电极丝。
本发明所要解决的第二个技术问题是针对现有技术而提供一种断丝频次低的高效冲洗电极丝。
本发明所要解决的第三个技术问题是针对现有技术而提供一种生产工艺简单、可操作性强的上述高效冲洗电极丝的制备方法。
本发明解决上述第一、第二个技术问题所采用的技术方案为：一种高效冲洗电极丝，包括芯材，其特征在于，所述芯材的表面具有沿其表面延伸的条状凸起，各条状凸起间隔设置，且各条状凸起的底缘均扩散至芯材中而形成凸起边缘；上述芯材中铜的质量百分数含量为58.5～67.5wt％，余量为锌及不可避免杂质，且该不可避免杂质的质量百分数含量小于等于0.5wt％；上述条状凸起中锌的质量百分数含量为57.8～69.8wt％，余量为铜及不可避免的杂质，且该不可避免杂质的质量百分数含量小于等于0.3wt％。
上述方案中，铜含量为58.5～67.5wt％的芯材材质，具有良好的抗拉强度和足够塑韧性。因为在电火花放电加工过程中，电极丝须能承受一定的张力和因放电引起的冲击力，如果材料强度太低或者断裂韧性太低，会造成电极丝抖动，最终导致切割工件表面粗糙 不平，甚至会引起多道切割线痕，尤其是对于一些悬空状态下难加工的金属工件，如高硬度材料和耐高温超级合金材料等，切割时施加的张力(组成电极丝材料的强度)越大，越容易切割，同样塑韧性越好，越不容易断丝。作为优选，铜含量为61.5～64.5wt％，61.5～64.5wt％的铜含量还有助于电极丝恢复直度，有助于穿丝，以及韧性良好的电极丝材料对进行锥度切割加工也是有益的。锌含量为57.8～69.8wt％的条状凸起，气化性能非常好，特别有利于提高切割效率。由于条状凸起中锌含量相对较高，大量气化后的锌会把切割中放电产生的能量带到切割金属的表面，并改善冲洗效果，同时锌气化所产生的气压还会把放电产生的蚀物吹走，为下一个脉冲放电创造更好的环境，有利于加工速度。因此条状凸起锌含量越高，切割效果就越好，但如果锌含量过高，会导致熔点较低、汽化焓减小，反而不利于提高加工效率。然而，根据铜锌二元相图，锌含量为57.8～69.8wt％具有γ相组织结构，因为γ相组织比较硬而脆，加工性能较差，则通过设置凸起边缘可以增加条状凸起与芯材结合力，有效杜绝由于凸起脱落引起的掉粉。另外，锌含量为43.5～53.5wt％凸起边缘具有β相组织，该相组织导电性能良好，能有效地传递放电能量，从而提高放电切割效率。
作为优选，所述条状凸起呈螺旋线状分布在上述芯材的表面。众所周知，电火花线切割稳定切割的前提首先必须保证在切割过程中不断丝，而断丝概率大小主要与电极丝自身散热性能、冷却状态及排屑性能等相关。本发明提供的条状凸起结构能显著增大丝材表面积，使得单位时间内，显著增加电极丝自身散失的热量，从而避免过多的热量损耗在电极丝上，导致电极丝因过热而烧断。当上下悬空工件，工作液冲水压力不足时，切割完毕后的切割工件表面覆盖着胶粘的甚至是粉末状的蚀除产物，这主要是伴随着放电通道内10000℃以上的高温，工作介质将分解生成大量的高分子化合物并与金属蚀除产物反应生成胶体状或颗粒状物质而形成的。这些物质将粘附在切缝内，并主要在切缝出口部位堆积，严重影响电蚀产物的排除，并使新鲜的工作介质进入切缝十分困难。木发明提供的电极丝随着电极丝放电加工的移动，特别是螺旋式的凸起结构，可以有效地注入更多的新鲜工作液，从而使工件和电极丝表面及时冷却，避免工件表面烧伤或者损伤电极丝，严重时引起烧丝。放电结束后，电极丝螺旋式的条状凸起结构可以存储大量蚀除产物，减少加工屑黏附到电极丝表面，从而改善排屑性能，减少断丝机率。因为黏附物起到了使放电集中在电极丝上的作用，此时若冷却散热条件差，就很可能使该处的温度升高，这样一来在连续放电中就可能继续有其他加工屑黏附在该点附近，如此造成一种恶性循环，最后导致该处烧伤，甚至断丝。此外，螺旋线状条状凸起围绕着芯材表面盘旋而下，对工作液自上而下具有良好的导流作用和自冲洗效果，因为工作液沿着电极丝表面螺旋状下落，使得走丝过程中形成通畅的液体柱提高自冲洗能力，降低电极丝表面压力，增强冷却能力，防止电极丝由于温度过高而造成的烧断，从而提高切割安全系数，降低断线频次。同时，这种螺旋线状条状凸起使得工作液沿切线方向流入，避 免与电极丝表面碰撞，确保液体旋转状下落，形成较为密实的旋转水流，极大的吸收了电火花线切割时产生大量的热量，防止断丝。数控低速走丝电火花线切割过程中，通常都采用高压冲水，因为水流的速度比较快，没有任何缓解，因此在切割过程中会造成较大的能量损失，非常不利于提升切割效率，这种螺旋线状条状凸起不仅使得流经电极丝表面的高压冲水不容易发生阻塞，还可以让冲水速度更加稳定，避免放电能量散失过早，有利于提升切割效率。
作为优选，所述条状凸起沿其长度方向呈连续状或不连续状分布在芯材表面上。
作为优选，所述条状凸起的横截面为梯形、矩形、三角形或锯齿形中的其中一种。
作为优选，所述条状凸起相对于芯材表面的径向延伸距离为4～20μm。
作为优选，所述条状凸起的相邻凸起段中，其中一凸起段的一侧与另一凸起段的同一侧的轴向距离为2～80μm。
作为优选，所述条状凸起的相邻凸起段所成的夹角为0～60°。
作为优选，所述凸起边缘中锌的质量百分数含量为43.5～53.5wt％，余量为铜及不可避免的杂质，且该不可避免杂质的质量百分数含量小于等于0.12wt％。锌含量为43.5～53.5wt％凸起边缘具有β相组织，该相组织导电性能良好，有效的传递放电能量，从而提高放电切割效率。
作为优选，所述凸起边缘沿径向的最大尺寸为1.5～8μm。进而通过该凸起边缘能使条状凸起与芯材更好地结合，进而能更有效地杜绝因条状凸起脱落而引起的掉粉。
本发明解决上述第三个技术问题所采用的技术方案为：一种如上所述的高效冲洗电极丝的制备方法，其特征在于，包括以下步骤：
(1)制备芯材所需的母线直径为0.5～1.2mm；
(2)将所制母线进行除油-酸洗-水洗-镀锌处理，锌镀层厚度为3～15um，制得第一线坯，其中电镀电流为1200～2500A，电压120～220V：
(3)对上述制得的第一线坯进行合金化热处理，温度为290～350℃，热处理时间为3～8h，在芯材表面形成上述条状凸起材质，制得第二线坯：
(4)对上述制得的第二线坯进行接触式在线扩散退火，使得在芯材和凸起之间形成上述凸起边缘材质，制得第三线坯，加工速度为10～20m/min，退火电流为25～100A，电压50～180V；
(5)最后，对上述制得的第三线坯采用异形模具进行旋转式连拉连退加工，拉伸速度为800～1200m/min，退火电压为12～60V，退火电流为15～50A，制得直径为0.15～0.30mm的电极丝成品
与现有技术相比，本发明的优点在于：本发明中芯材表面凸设有条状凸起，且各条状凸起间隔均设，从而能显著增大电极丝的表面积，明显增加单位时间内电极丝自身散失的热量，进而避免电极丝损耗过多的热量而导致电极丝因过热而烧断。
本发明中的电极丝在加工上下悬空工件时，通过上述条状凸起结构可有效的注入更多的新鲜工作液，从而使工件和电极丝表面及时冷却，避免工件表面烧伤或者损伤电极丝，严重时引起烧丝。放电结束后，上述条状凸起结构可以存储大量蚀除产物，减少加工屑黏附到电极丝表面，从而改善排屑性能，减少断丝机率。
本发明中芯材含铜量为58.5～67.5wt％，使得该芯材具有良好的抗拉强度和足够塑韧性，进而使得本发明中的电极丝具有较大的张力和较好的塑料韧性，进而获得较好的切割性能且不容易断丝。条状凸起的锌含量为57.8～69.8wt％，从而使得电极丝的气化性能较好，有利于提高切割效率。此外，条状凸起具有γ相组织结构，因而通过设置凸起边缘可以增加条状凸起与芯材结合力，有效杜绝由于条状凸起脱落引起的掉粉。
总之，本发明的电极丝切割效率高，尤其适合上下悬空或带有一定锥度的高硬度合金或耐高温材料的切割加工。本发明的制备方法生产工艺简单，可操作性强，制备步骤少，生产设备简单，易于制得符合要求的产品，且易于实现规模化、自动化生产。
附图说明
图1为本发明实施例中电极丝的结构示意图(条状凸起连续分布)；
图2为本发明实施例中电极丝的结构示意图(条状凸起不连续分布)；
图3为图2中I部分的放大图；
图4为本发明实施例中电极丝的制备过程示意图(条状凸起不连续分布)；
图5为本发明实施例中电极丝的显微照片图(条状凸起连续分布)；
图6为本发明实施例中电极丝的显微照片图(条状凸起不连续分布)。
具体实施方式
以下结合附图实施例对本发明作进一步详细描述。
本发明中的高效冲洗电极丝的制备过程如下：取制备芯材所需的铜锌合金拉伸加工成直径0.5～1.2mm的母线(如图4-A所示)，将所制母线进行除油-酸洗-水洗-镀锌处理，锌镀层厚度为3～15um，制得第一线坯(如图4-B所示)，其中电镀电流为1200～2500A，电压120～220V。对上述制得的第一线坯进行合金化热处理，温度为290～350℃，热处理时间为3～8h，在芯材表而形成凸起材质，制得第二线坯(如图4-C所示)。对上述制得的第二线坯进行接触式在线扩散退火处理，使得在芯材和凸起之间形成上述凸起边缘材质，制得第三线坯(如图4-D所示)，其中，加工速度为10～20m/min，退火电流为25～100A，电压50～180V。最后对上述制得的第三线坯采用异形模具进行旋转式连拉连退加工，拉伸速度为800～1200m/min，退火电压为12-60V，退火电流为15～50A，制得直径为0.15～0.30mm的电极丝成品(如图4-E所示，该图4-E为图2的剖 视图)，其显微照片如图5和图6所示，该电极丝成品的芯材表面形成上述的条状凸起。
制得的电极丝成品如图1～3所示，其包括芯材1，芯材1的表面具有沿其表面延伸的条状凸起2，各条状凸起2间隔设置，且各条状凸起2的底缘均扩散至芯材1中而形成凸起边缘22。本实施例中，如图1所示，该条状凸起2呈螺旋线状分布在上述芯材1的表面上，并且沿其长度方向连续分布；如图2所示，该条状凸起2沿其长度方向不连续分布。本实施例中，该条状凸起2的横截面优选为梯形，当然该条状凸起2的横截面的形状也可以是矩形、三角形或锯齿形中的任意一种。进一步，条状凸起2相对于芯材表面1的径向延伸距离L为4～20μm。
由上可见，本发明中的条状凸起2呈螺旋线状分布在芯材1表面并呈连续状，因而该条状凸起2的螺旋线数N可为1、2、3或4。本实施例中，优选地，条状凸起2的螺旋线数为1，该条状凸起2中的相邻凸起段21中，其中一凸起段21的一侧与另一凸起段21的同一侧的轴向距离P为2～80μm，条状凸起2的相邻凸起段21所成的夹角α为0～60°，而上述凸起边缘22沿径向的最大尺寸S为1.5～8μm。当上述螺旋线数N为2、3或4，则同一条状凸起2上的相邻凸起段21中，其中一凸起段21的一侧与另一凸起段21的同一侧的轴向距离为NP。
此外，本发明中的电极丝的元素组成如下：芯材中铜的质量百分数含量为58.5～67.5wt％，余量为锌及不可避免杂质，且该不可避免杂质的质量百分数含量小于等于0.5wt％。条状凸起中锌的质量百分数含量为57.8～69.8wt％，余量为铜及不可避免的杂质，且该不可避免杂质的质量百分数含量小于等于0.3wt％。凸起边缘中锌的质量百分数含量为43.5～53.5wt％，余量为铜及不可避免的杂质，且该不可避免杂质的质量百分数含量小于等于0.12wt％。
本发明实施例1～12采用上述制备方法，制得具有上述元素组成以及结构的高效冲洗电极丝，具体元素含量、条状凸起特征以及性能参见表1、表2以及表3。
比较例1：市售H62黄铜电极丝，直径为0.25mm。
比较例2：
一种镀锌电极丝，由直径为0.9～1.2mm的H63黄铜组成芯材，在芯材表面直接镀锌，镀层厚度为10～20um，然后再进行连拉连退加工，制成直径为0.25mm的镀锌电极丝。
比较例3：
一种高速电极丝，由直径为0.9～1.2mm的H60黄铜组成芯材，然后在芯材表面镀锌，镀层厚度为10～30um，得到第一线坯，对第一线坯进行热处理，热处理工艺的温度为410℃，时间为10h，得到第二线坯，最后对热处理后的第二线坯进行连拉连退加工，制成直径为0.25mm的高速电极丝，表层结构为γ相。
比较例4：
一种高速电极丝，由直径为0.9～1.2mm的H63黄铜组成芯材，然后在芯材表面镀锌，镀层厚度为10～30um，得到第一线坯，对第一线坯进行热处理，热处理工艺的温度为550℃，时间为20h，得到第二线坯，最后对热处理后的第二线坯进行连拉连退加工，制成直径为0.25mm的高速电极丝，表层结构为β相。
比较例5-8：制备方法与实施例中相同。对比例1～8的电极丝的具体元素含量、条状凸起特征以及性能参见表1、表2以及表3。
上述实施例1～12及比较例1～8制备的最终成型的电极丝，在万能电子拉伸仪上测试其物理性能(抗拉强度和延伸率)，以718镍基合金做为料件测试所制备的最终成型的电极丝的断丝频率及切割效率，所测试的数据如表3所示。
表1各实施例和比较例中电极丝的元素含量
Figure PCTCN2018000333-appb-000001
表2各实施例和比较例中条状凸起的特征
Figure PCTCN2018000333-appb-000002
表3各实施例和比较例电极丝的性能数据
Figure PCTCN2018000333-appb-000003
Figure PCTCN2018000333-appb-000004
注：表3中的各数据均在同等条件下测试获得，其中电极丝的直径均为0.25mm，当然本领域的技术人员可有效调整各实施例中对第一线坯的连拉连退加工条件和对第二线坯的热处理条件，使得各实施例中的成品电极丝的直径在0.15～0.30mm的范围内变化。其中，以比较例1的切割效率为基准，实施例1～12以及比较例2～8的切割效率与其比值作为体现它们切割效率的性能参数。
通过上述实施例的性能测试可见，与对比例中的电极丝相比，本发明中的电极丝在保证其物理性能的基础上，能有效减少断丝机率，提高切割效率。

Claims (10)

  1. 一种高效冲洗电极丝，包括芯材，其特征在于，所述芯材的表面具有沿其表面延伸的条状凸起，各条状凸起间隔设置，且各条状凸起的底缘均扩散至芯材中而形成凸起边缘；
    上述芯材中铜的质量百分数含量为58.5～67.5wt％，余量为锌及不可避免杂质，且该不可避免杂质的质量百分数含量小于等于0.5wt％；
    上述条状凸起中锌的质量百分数含量为57.8～69.8wt％，余量为铜及不可避免的杂质，且该不可避免杂质的质量百分数含量小于等于0.3wt％。
  2. 如权利要求1所述的高效冲洗电极丝，其特征在于，所述条状凸起呈螺旋线状分布在上述芯材的表面。
  3. 如权利要求2所述的高效冲洗电极丝，其特征在于，所述条状凸起沿其长度方向呈连续或不连续分布。
  4. 如权利要求2所述的高效冲洗电极丝，其特征在于，所述条状凸起的横截面为梯形、矩形、三角形或锯齿形中的其中一种。
  5. 如权利要求1～4任一项所述的高效冲洗电极丝，其特征在于，所述条状凸起相对于芯材表面的径向延伸距离为4～20μm。
  6. 如权利要求2～4任一项所述的高效冲洗电极丝，其特征在于，所述条状凸起的相邻凸起段中，其中一凸起段的一侧与另一凸起段的同一侧的轴向距离为2～80μm。
  7. 如权利要求1～4任一项所述的高效冲洗电极丝，其特征在于，所述条状凸起的相邻凸起段所成的夹角为0～60°。
  8. 如权利要求1～4任一项所述的高效冲洗电极丝，其特征在于，所述凸起边缘中锌的质量百分数含量为43.5～53.5wt％，余量为铜及不可避免的杂质，且该不可避免杂质的质量百分数含量小于等于0.12wt％。
  9. 如权利要求8所述的高效冲洗电极丝，其特征在于，所述凸起边缘沿径向的最大尺寸为1.5～8μm。
  10. 一种如权利要求1～9任一项所述的高效冲洗电极丝的制备方法，其特征在于，包括以下步骤：
    (1)制备芯材所需的母线直径为0.5～1.2mm；
    (2)将所制母线进行除油-酸洗-水洗-镀锌处理，锌镀层厚度为3～15um，制得第一线坯，其中电镀电流为1200～2500A，电压120～220V；
    (3)对上述制得的第一线坯进行合金化热处理，温度为290～350℃，热处理时间为3～8h，在芯材表面形成条状凸起材质，制得第二线坯：
    (4)对上述制得的第二线坯进行接触式在线扩散退火处理，使得在芯材和凸起之间形成上述凸起边缘材质，制得第三线坯，加工速度为10～20m/min，退火电流为 25～100A，电压50～180V；
    (5)最后，对上述制得的第三线坯采用异形模具进行旋转式连拉连退加工，拉伸速度为800～1200m/min，退火电压为12～60V，退火电流为15～50A，制得直径为0.15～0.30mm的电极丝成品。
PCT/CN2018/000333 2017-12-31 2018-09-20 一种高效冲洗电极丝及其制备方法 WO2019127614A1 (zh)

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