WO2020232791A1 - Combined electric spark grinding machining tool, tool manufacturing method and machining method - Google Patents
Combined electric spark grinding machining tool, tool manufacturing method and machining method Download PDFInfo
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- WO2020232791A1 WO2020232791A1 PCT/CN2019/092567 CN2019092567W WO2020232791A1 WO 2020232791 A1 WO2020232791 A1 WO 2020232791A1 CN 2019092567 W CN2019092567 W CN 2019092567W WO 2020232791 A1 WO2020232791 A1 WO 2020232791A1
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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
- B23H5/00—Combined machining
- B23H5/04—Electrical discharge machining combined with mechanical working
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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
- B23H5/00—Combined machining
- B23H5/06—Electrochemical machining combined with mechanical working, e.g. grinding or honing
- B23H5/08—Electrolytic grinding
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24D—TOOLS FOR GRINDING, BUFFING OR SHARPENING
- B24D5/00—Bonded abrasive wheels, or wheels with inserted abrasive blocks, designed for acting only by their periphery; Bushings or mountings therefor
- B24D5/06—Bonded abrasive wheels, or wheels with inserted abrasive blocks, designed for acting only by their periphery; Bushings or mountings therefor with inserted abrasive blocks, e.g. segmental
Definitions
- This application relates to the technical field of grinding processing tools, and in particular to an electric spark grinding composite processing tool, a tool preparation method and a processing method.
- the processing technology of superhard and hard-to-grind materials is an important field in advanced materials and advanced manufacturing technology. It is widely used in many industrial sectors of the aerospace industry, mold industry, automobile manufacturing and various special-purpose products.
- the processing of difficult-to-grind materials, low processing efficiency and high tool wear are traditional problems, which often require multiple rough/finish machining and multiple clamping and positioning, the process is cumbersome, and the machining error is difficult to control.
- EDM composite machining technology is an effective means to improve the processing efficiency of superhard and difficult-to-grind materials with electrical conductivity, and through the effective combination of EDM and abrasive cutting, high-quality machined surfaces can be obtained .
- most metal-based adhesives are not ideal tool electrode materials. In the rough machining stage, it is difficult to achieve high-energy EDM removal for large-depth machining, the abrasive particles fall off quickly, and the grinding wheel wears quickly.
- the main purpose of this application is to provide an EDM grinding composite machining tool, its preparation and its machining method, aiming to set up a grinding wheel tool with a high-performance electrode segment and a grinding segment alternately distributed within one clamping range
- this application proposes an EDM grinding composite machining tool, which includes a grinding wheel base, a grinding section and an electrode section.
- the grinding wheel base is in the shape of a disc, and the grinding section and the electrode section alternate It is arranged on the outer edge end surface of the grinding wheel base body.
- the grinding section is formed by uniformly mixing abrasive grains and a metal-based adhesive and then sintering, and the EDM loss rate of the electrode section is less than the EDM loss rate of the metal-based EDM of the grinding section.
- the metal-based adhesive is made of copper, tin mixed powder and or copper-tin alloy powder.
- a preparation method of electric spark grinding composite machining tool includes the steps:
- the grinding wheel base is processed on the base material of preset thickness
- the grinding wheel base body containing the electrode segments is put into a second mold and filled with a second preset material for sintering to obtain a first grinding wheel.
- the step of processing a grinding wheel matrix on a substrate with a predetermined thickness includes:
- the grinding wheel base is machined on stainless steel, brass or easy-turning iron with a thickness of 0.5mm-20mm.
- the step of putting the grinding wheel matrix into a first mold and filling the first preset material for sintering to obtain a grinding wheel matrix containing electrode segments includes:
- the grinding wheel matrix is put into a first mold and filled with pure copper powder, pure tungsten powder, brass powder or cupronickel powder for sintering to obtain a grinding wheel matrix containing electrode segments.
- the step of putting the grinding wheel base body containing the electrode segments into a second mold and filling with a second preset material for sintering to obtain the first grinding wheel includes:
- the grinding wheel matrix containing the electrode segments is put into a second mold and filled with a mixture of a metal-based binder and an abrasive for sintering to obtain a first grinding wheel.
- An electric spark grinding composite machining method proposed in this application includes the steps:
- the first grinding wheel is connected to the negative pole of the pulse power supply, and the workpiece is connected to the positive pole of the pulse power supply;
- the process parameters of the high-energy discharge refer to a processing voltage of 90-120V and a pulse width of 10-50 ⁇ s.
- the process parameters of the low-energy discharge refer to a processing voltage of 30-50V and a pulse width of 1-10 ⁇ s.
- An EDM grinding composite machining tool, preparation and machining method provided in this application by arranging a grinding wheel tool with a high-performance electrode segment and a grinding segment distributed alternately, the super hard and difficult can be completed within a single clamping range High efficiency rough machining and high quality finishing of grinding materials.
- FIG. 1 is a schematic diagram of the structure of an electric spark grinding composite machining tool according to an embodiment of the present application
- Figure 2 is a schematic diagram of EDM composite rough machining in another embodiment of the present application.
- Fig. 3 is a schematic diagram of EDM composite finishing in another embodiment of the present application.
- connection may be a direct connection or an indirect connection.
- an EDM composite machining tool which includes a grinding wheel base 1, a grinding section 5 and an electrode section 2.
- the grinding wheel base 1 is disc-shaped and is ground
- the segments 5 and the electrode segments 2 are alternately arranged on the outer edge end surface of the grinding wheel base 1.
- the EDM loss rate of electrode section 2 is less than the metal-based EDM loss rate of grinding section 5, which can prevent abrasive particles 3 from falling off quickly during the composite rough machining stage of EDM grinding, and improve the super hard and hard-to-wear The efficiency of rough machining of cutting materials.
- the low-energy electric spark discharge gap ⁇ 2 is smaller than the height of the abrasive particles 3, which can improve the surface quality of the finishing workpiece 6 made of super-hard and difficult-to-grind materials.
- the arc lengths of the grinding section 5 and the electrode section 2 are equal, and the grinding section 5 is formed by mixing and sintering abrasive particles 3 and a metal-based adhesive.
- the electrode section 2 is sintered from electrode material powder, and the EDM loss rate of the electrode material should be less than the EDM loss rate of the metal base 4.
- the workpiece 6 is rough-machined using the process parameters that form the high-energy discharge, so that the high-energy EDM discharge gap ⁇ 1 is greater than or equal to the height h of the abrasive grains.
- the EDM loss rate of electrode section 2 is slightly lower than that of grinding section 5 metal base 4 EDM, so the diameter of electrode section 2 is slightly larger than the diameter of the metal base 4 of grinding section 5, reaching electrode section 2 to grinding section 5
- the protective effect prevents the abrasive particles 3 from falling off quickly.
- the arc length of the grinding section and the electrode section can be adjusted.
- the grinding wheel base body 1 is made of stainless steel, brass or easy-turning iron.
- the material of the grinding wheel substrate 1 includes stainless steel, brass, and free-turning iron.
- the free-turning iron is free-cutting steel.
- the metal machinability is enhanced by adding elements such as sulfur or lead, and the machine tool cutting performance is good.
- the outer diameter of the grinding wheel base 1 ranges from 40 mm to 200 mm
- the inner diameter of the grinding wheel base 1 ranges from 12 mm to 35 mm
- the thickness of the grinding wheel base 1 ranges from 0.5 mm to 20 mm.
- the electrode section 2 is made of pure copper powder, pure tungsten powder, brass powder or cupronickel powder. Copper has high electrical conductivity, thermal conductivity, abrasion resistance and excellent process performance, with a particle size range of 1 ⁇ m ⁇ 20 ⁇ m.
- the abrasive particles 3 are made of diamond particles, boron carbide particles or silicon carbide abrasive materials. Diamond, boron carbide and silicon carbide have the characteristics of low density, high strength, high temperature stability and good chemical stability, and the particle size ranges from 0.1 ⁇ m to 10 ⁇ m.
- the metal binder is made of copper, tin mixed powder and or copper-tin alloy powder.
- the particle size range of copper and tin mixed powder is 1 ⁇ m-20 ⁇ m, and the particle size range of copper-tin alloy powder is 25 ⁇ m-50 ⁇ m.
- the grinding section 5 and the electrode section 2 need to be respectively sintered to the circumference of the grinding wheel base 1 and alternately connected to form a grinding wheel tool.
- the arc length of the grinding section 5 and the electrode section 2 can be adjusted.
- the grinding section 5 is made by uniformly mixing the metal-based adhesive and abrasive particles and then sintered;
- the electrode section 2 is made by sintering the electrode material powder, and the EDM loss rate of the electrode material should be less than that of the metal-based adhesive. Processing loss rate.
- an EDM grinding composite machining tool the EDM grinding composite machining tool has an annular array form, and the grinding wheel tool is composed of an electrode section 2 and a grinding section 5 composed of high-performance electrode materials. Distribution composition.
- the grinding wheel base 1 in this embodiment is disc-shaped, and the grinding section 5 and the electrode section 2 are alternately arranged on the outer edge end surface of the grinding wheel base 1.
- the grinding section 5 is formed by mixing and sintering abrasive particles 3 and a metal-based binder ,
- the EDM loss rate of the electrode section 2 is less than that of the metal base 4.
- the grinding wheel base 1 into the first mold and fill the blank of the outer circle with copper powder for sintering to obtain a ring-shaped array electrode section 2 Grinding wheel base body; then put the grinding wheel base body containing the annular array electrode segment 2 into the second mold, fill the mixed powder of copper powder, tin powder and diamond abrasive in the blank of the outer circle, and perform sintering again to obtain the electrode segment 2 and the grinding wheel.
- the cutting segments 5 are alternately connected to form a complete grinding wheel of the outer circle of the grinding wheel tool. With this special grinding wheel tool, high-efficiency rough machining and high-quality finishing of super-hard and difficult-to-grind materials can be completed within a clamping range.
- an EDM grinding composite machining tool the EDM grinding composite machining tool has an annular array form, and the grinding wheel tool is composed of an electrode section 2 and a grinding section 5 composed of high-performance electrode materials. Distribution composition.
- the grinding wheel base 1 in this embodiment is disc-shaped.
- the grinding section 5 and the electrode section 2 are alternately arranged on the outer edge end surface of the grinding wheel base 1.
- the grinding section 5 is made by mixing abrasive particles 3 and a metal-based binder.
- the EDM loss rate of the electrode section 2 is less than the loss rate of the metal base 4 of the grinding section 5.
- the electrode section in this embodiment is mixed and sintered with copper, tin mixed powder and copper-tin alloy powder, and then contains the ring array electrode
- the grinding wheel matrix of section 2 is placed in the second mold, and the mixed powder of boron carbide granules and copper-tin alloy powder is filled in the outer circle.
- the grinding wheel matrix 1 is processed on a 20mm thick free-wheeling iron.
- the special grinding wheel tool can complete the high-efficiency rough machining and high-quality finishing of super-hard and difficult-to-grind materials within a single clamping range.
- This embodiment proposes a method for preparing an EDM grinding composite machining tool based on the above specific embodiment 1, including the steps:
- the grinding wheel base 1 is processed on a stainless steel plate with a thickness of 15mm by using the wire EDM process; stainless steel has strong wear resistance.
- the grinding wheel base 1 containing the electrode segment 2 into the second mold and fill it with copper, tin mixed powder and diamond abrasive grains, and then sinter it to obtain the complete outer circle of the grinding wheel tool containing electrode segments 2 and grinding segments 5 alternately connected Grinding wheel.
- This embodiment is based on the method for preparing an EDM grinding composite machining tool proposed in the foregoing specific embodiment 2, and includes the steps:
- the grinding wheel base 1 is machined on the easy-turning iron with a thickness of 10mm by using the electric discharge wire cutting process; the easy-turning iron has strong wear resistance.
- the grinding wheel base 1 is put into the first mold and filled with pure tungsten powder for sintering to obtain the grinding wheel base 1 containing the electrode segment 2.
- the grinding wheel base body 1 containing the electrode segment 2 into the second mold and fill it with boron carbide granules and copper-tin alloy powder, and then sinter it to obtain the second electrode segment 2 and the grinding segment 5 alternately connected to form the outer circle of the grinding wheel tool One grinding wheel.
- the first grinding wheel is connected to the negative pole of the pulse power supply, and the workpiece 6 is connected to the positive pole of the pulse power supply;
- the material of the workpiece 6 is titanium alloy, hard alloy, silicon carbide or conductive ceramic.
- the first height in this embodiment refers to setting the high-energy electric spark discharge gap to ⁇ 1; using the high-energy discharge process parameters to perform rough machining on the workpiece 6; making the electrode segment 2 discharge
- the gap ⁇ 1 is greater than or equal to the height h of the abrasive grain exiting edge, which realizes high-efficiency and high-energy EDM rotary machining, and the grinding wheel grinding section 5 completes the edge extraction.
- the EDM loss rate of electrode section 2 is less than the metal base EDM loss rate of grinding section 5, so that the diameter of electrode section 2 is greater than the metal base diameter of grinding section 5. After that, electrode section 2 protects the grinding section 5 and prevents The abrasive particles 3 fall off quickly.
- the second height in this embodiment refers to setting the low-energy electric spark discharge gap to ⁇ 2; use the low-energy discharge process parameters to finish machining the workpiece 6 so that the electrode segment 2 discharges
- the gap is less than or equal to the height h of the abrasive grain exiting edge, which realizes high-precision electric discharge grinding and rotation processing, and obtains a workpiece 6 with a high-quality processing surface.
- the process parameters of high-energy discharge refer to a processing voltage of 90-120V and a pulse width of 10-50 ⁇ s; the process parameters of low-energy discharge refer to a processing voltage of 30-50 V and a pulse width of 1-10 ⁇ s.
- This embodiment is based on the electric spark grinding composite machining method proposed in the above specific embodiment 1, and includes the steps:
- the first grinding wheel and the workpiece 6 are respectively installed on the grinder, the first grinding wheel is connected to the negative electrode of the pulse power supply, and the workpiece 6 is connected to the positive electrode of the pulse power supply; the material of the workpiece 6 in this embodiment is conductive ceramic.
- the grinding wheel grinding section 5 completes the cutting edge.
- the EDM loss rate of electrode section 2 is less than the metal base EDM loss rate of grinding section 5, so that the diameter of electrode section 2 is greater than the metal base diameter of grinding section 5. After that, electrode section 2 protects the grinding section 5 and prevents The abrasive particles 3 fall off quickly.
- the process parameters of high-energy discharge refer to a processing voltage of 120V and a pulse width of 50 ⁇ s; the process parameters of low-energy discharge refer to a processing voltage of 50 V and a pulse width of 10 ⁇ s.
- This embodiment is based on the above-mentioned specific embodiment 2 and proposed an electric spark grinding composite machining method, including the steps:
- the first grinding wheel and the workpiece 6 are respectively installed on the grinding machine, the first grinding wheel is connected to the negative electrode of the pulse power supply, and the workpiece 6 is connected to the positive electrode of the pulse power supply;
- the material of the workpiece 6 in this embodiment is silicon carbide.
- Silicon carbide also known as emery, is made by smelting raw materials such as quartz sand, petroleum coke (or coal coke), wood chips (salt is needed to produce green silicon carbide) through a high temperature resistance furnace. Silicon carbide is also a rare mineral in nature. Silicon carbide is also called moissanite.
- silicon carbide is the most widely used and most economical one, and it can be called gold steel grit or refractory grit. Silicon carbide has stable chemical properties, high thermal conductivity, low thermal expansion coefficient and good wear resistance.
- the grinding wheel grinding section 5 completes the cutting edge.
- the EDM loss rate of electrode section 2 is less than the metal base EDM loss rate of grinding section 5, so that the diameter of electrode section 2 is greater than the metal base diameter of grinding section 5. After that, electrode section 2 protects the grinding section 5 and prevents The abrasive particles 3 fall off quickly.
- the process parameters of high energy discharge refer to a processing voltage of 100V and a pulse width of 40 ⁇ s; the process parameters of low energy discharge refer to a processing voltage of 40 V and a pulse width of 5 ⁇ s.
- the electric spark grinding composite machining tool of the present application can complete high-efficiency rough machining and high-quality finishing of super-hard and difficult-to-grind materials within a clamping range.
- use process parameters that can form high-energy discharge so that the high-energy EDM discharge gap ⁇ 1 is greater than the height h of the abrasive grain, to achieve high-efficiency and high-energy EDM rotary machining, and the grinding section of the grinding wheel completes the edge;
- process parameters that can form low-energy discharge make the low-energy EDM discharge gap ⁇ 2 less than or equal to the height of the abrasive grains, h, and realize high-precision EDM rotary machining.
- an electric spark grinding composite machining tool, preparation and machining method thereof, by setting a high-performance electrode segment and a grinding wheel tool distributed alternately with the grinding segment, can complete the super-hard and difficult High efficiency rough machining and high quality finishing of grinding materials.
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Abstract
Provided is a combined electric spark grinding machining tool, comprising a grinding wheel matrix (1), grinding sections (5), and electrode sections (2). The grinding wheel matrix (1) is of a disc shape, the grinding sections (5) and the electrode sections (2) are alternately arranged on an end face of an outer edge of the grinding wheel matrix (1), and by arranging a grinding wheel tool with the electrode sections (2) and the grinding sections (5) alternately arranged, rough machining and finishing machining of super-hard and difficult-to-grind materials can be completed within a one-time clamping range. Further provided are a manufacturing method for the combined electric spark grinding machining tool and a combined electric spark grinding machining method.
Description
本申请要求于2019年05月21日提交中国专利局、申请号为2019207527108,发明名称为“一种电火花磨削复合加工工具”的中国专利申请的优先权,其全部内容通过引用结合在本申请中。This application claims the priority of a Chinese patent application filed with the Chinese Patent Office on May 21, 2019, with application number 2019207527108, and the title of the invention "a kind of electric spark grinding composite machining tool", the entire content of which is incorporated herein by reference Applying.
本申请涉及磨削加工工具技术领域,尤其涉及一种电火花磨削复合加工工具、工具制备方法及加工方法。This application relates to the technical field of grinding processing tools, and in particular to an electric spark grinding composite processing tool, a tool preparation method and a processing method.
超硬与难磨削的材料加工技术是先进材料和先进制造技术中的重要领域,在航空航天工业、模具业、汽车制造业及各种特殊用途产品众多产业部门得到广泛应用,对于超硬与难磨削材料的加工,加工效率较低和工具损耗较大是传统问题,往往需要进行多道粗/精加工和多次装夹定位,工艺过程繁琐,加工误差较难控制。The processing technology of superhard and hard-to-grind materials is an important field in advanced materials and advanced manufacturing technology. It is widely used in many industrial sectors of the aerospace industry, mold industry, automobile manufacturing and various special-purpose products. The processing of difficult-to-grind materials, low processing efficiency and high tool wear are traditional problems, which often require multiple rough/finish machining and multiple clamping and positioning, the process is cumbersome, and the machining error is difficult to control.
电火花磨削复合加工技术是提高具有导电能力的超硬与难磨削材料加工效率的有效手段,并且通过对电火花放电蚀除和磨粒切削的有效复合,可以获得较高质量的加工表面。但是,大多数金属基粘接剂不是理想的工具电极材料,在粗加工阶段,较难实现大深度加工的高能电火花蚀除,磨粒较快脱落,砂轮损耗较快。EDM composite machining technology is an effective means to improve the processing efficiency of superhard and difficult-to-grind materials with electrical conductivity, and through the effective combination of EDM and abrasive cutting, high-quality machined surfaces can be obtained . However, most metal-based adhesives are not ideal tool electrode materials. In the rough machining stage, it is difficult to achieve high-energy EDM removal for large-depth machining, the abrasive particles fall off quickly, and the grinding wheel wears quickly.
本申请的主要目的为提供一种电火花磨削复合加工工具、制备及其加工方法,旨在通过设置高性能电极段与磨削段相间分布的砂轮工具,在一次装夹范围内即可完成超硬与难磨削材料的高效率粗加工和高质量精加工的技术问题。The main purpose of this application is to provide an EDM grinding composite machining tool, its preparation and its machining method, aiming to set up a grinding wheel tool with a high-performance electrode segment and a grinding segment alternately distributed within one clamping range Technical problems of high-efficiency rough machining and high-quality finishing of super-hard and difficult-to-grind materials.
为了实现上述申请目的,本申请提出一种电火花磨削复合加工工具,包括砂轮基体、磨削段和电极段,所述砂轮基体为圆盘状,所述磨削段与所述电极段交替设置于所述砂轮基体的外缘端面。In order to achieve the purpose of the above application, this application proposes an EDM grinding composite machining tool, which includes a grinding wheel base, a grinding section and an electrode section. The grinding wheel base is in the shape of a disc, and the grinding section and the electrode section alternate It is arranged on the outer edge end surface of the grinding wheel base body.
所述磨削段由磨粒和金属基粘接剂匀混合后烧结而成,所述电极段电火花加工损耗速率小于所述磨削段金属基的电火花加工损耗速率。The grinding section is formed by uniformly mixing abrasive grains and a metal-based adhesive and then sintering, and the EDM loss rate of the electrode section is less than the EDM loss rate of the metal-based EDM of the grinding section.
所述金属基粘接剂由铜、锡混合粉末和或铜锡合金粉末制成。The metal-based adhesive is made of copper, tin mixed powder and or copper-tin alloy powder.
一种电火花磨削复合加工工具的制备方法,包括步骤:A preparation method of electric spark grinding composite machining tool includes the steps:
在预设厚度的基材上加工出砂轮基体;The grinding wheel base is processed on the base material of preset thickness;
将所述砂轮基体放入第一模具中填充第一预设材料进行烧结,获得含有电极段的砂轮基体;Putting the grinding wheel base into a first mold and filling it with a first preset material for sintering, to obtain a grinding wheel base containing electrode segments;
将所述含有电极段的砂轮基体放入第二模具中填充第二预设材料进行烧结,获得第一砂轮。The grinding wheel base body containing the electrode segments is put into a second mold and filled with a second preset material for sintering to obtain a first grinding wheel.
所述在预设厚度的基材上加工出砂轮基体的步骤,包括:The step of processing a grinding wheel matrix on a substrate with a predetermined thickness includes:
在厚度为0.5mm-20mm的不锈钢、黄铜或易车铁上加工出砂轮基体。The grinding wheel base is machined on stainless steel, brass or easy-turning iron with a thickness of 0.5mm-20mm.
所述将所述砂轮基体放入第一模具中填充第一预设材料进行烧结,获得含有电极段的砂轮基体的步骤,包括:The step of putting the grinding wheel matrix into a first mold and filling the first preset material for sintering to obtain a grinding wheel matrix containing electrode segments includes:
所述将所述砂轮基体放入第一模具中填充纯铜粉末、纯钨粉末、黄铜粉末或白铜粉末进行烧结,获得含有电极段的砂轮基体。The grinding wheel matrix is put into a first mold and filled with pure copper powder, pure tungsten powder, brass powder or cupronickel powder for sintering to obtain a grinding wheel matrix containing electrode segments.
所述将所述含有电极段的砂轮基体放入第二模具中填充第二预设材料进行烧结,获得第一砂轮的步骤,包括:The step of putting the grinding wheel base body containing the electrode segments into a second mold and filling with a second preset material for sintering to obtain the first grinding wheel includes:
将所述含有电极段的砂轮基体放入第二模具中填充金属基粘结剂和磨料的混合体进行烧结,获得第一砂轮。The grinding wheel matrix containing the electrode segments is put into a second mold and filled with a mixture of a metal-based binder and an abrasive for sintering to obtain a first grinding wheel.
本申请提出的一种电火花磨削复合加工方法,包括步骤:An electric spark grinding composite machining method proposed in this application includes the steps:
将第一砂轮和工件分别安装在磨床上,所述第一砂轮接脉冲电源负极,所述工件接脉冲电源正极;Install the first grinding wheel and the workpiece on the grinding machine respectively, the first grinding wheel is connected to the negative pole of the pulse power supply, and the workpiece is connected to the positive pole of the pulse power supply;
将所述第一砂轮调整到第一高度;使用高能量放电的工艺参数对所述工件进行粗加工;Adjust the first grinding wheel to a first height; use high-energy discharge process parameters to rough machine the workpiece;
将所述第一砂轮调整到第二高度;使用低能量放电的工艺参数对所述工件进行精加工,得到高品质加工面的工件。Adjust the first grinding wheel to a second height; use low-energy discharge process parameters to finish machining the workpiece to obtain a workpiece with a high-quality machining surface.
所述高能量放电的工艺参数指加工电压为90-120V,脉宽为10-50μs。The process parameters of the high-energy discharge refer to a processing voltage of 90-120V and a pulse width of 10-50 μs.
所述低能量放电的工艺参数指加工电压为30-50V,脉宽为1-10μs。The process parameters of the low-energy discharge refer to a processing voltage of 30-50V and a pulse width of 1-10μs.
本申请中提供的一种电火花磨削复合加工工具、制备及其加工方法,通过设置高性能电极段与磨削段相间分布的砂轮工具,在一次装夹范围内即可完成超硬与难磨削材料的高效率粗加工和高质量精加工。An EDM grinding composite machining tool, preparation and machining method provided in this application, by arranging a grinding wheel tool with a high-performance electrode segment and a grinding segment distributed alternately, the super hard and difficult can be completed within a single clamping range High efficiency rough machining and high quality finishing of grinding materials.
图1是本申请一实施例的电火花磨削复合加工工具的结构示意图;FIG. 1 is a schematic diagram of the structure of an electric spark grinding composite machining tool according to an embodiment of the present application;
图2是本申请另一实施例的电火花磨削复合粗加工的示意图;Figure 2 is a schematic diagram of EDM composite rough machining in another embodiment of the present application;
图3是本申请另一实施例的电火花磨削复合精加工的示意图。Fig. 3 is a schematic diagram of EDM composite finishing in another embodiment of the present application.
下面将结合本申请实施例中的附图,对本申请实施例中的技术方案进行清楚、完整地描述,显然,所描述的实施例仅仅是本申请的一部分实施例,而不是全部的实施例。基于本申请中的实施例,本领域普通技术人员在没有作出创造性劳动前提下所获得的所有其它实施例,都属于本申请保护的范围。The technical solutions in the embodiments of the present application will be clearly and completely described below in conjunction with the drawings in the embodiments of the present application. Obviously, the described embodiments are only a part of the embodiments of the present application, rather than all the embodiments. Based on the embodiments in this application, all other embodiments obtained by those of ordinary skill in the art without creative work shall fall within the protection scope of this application.
需要说明,本申请实施例中所有方向性指示(诸如上、下、左、右、前、后……)仅用于解释在某一特定姿态(如附图所示)下各部件之间的相对位置关系、运动情况等,如果该特定姿态发生改变时,则该方向性指示也相应地随之改变,所述的连接可以是直接连接,也可以是间接连接。It should be noted that all directional indications (such as up, down, left, right, front, back...) in the embodiments of this application are only used to explain the difference between components in a specific posture (as shown in the accompanying drawings). If the relative positional relationship, movement situation, etc. change, the directional indication changes accordingly. The connection may be a direct connection or an indirect connection.
另外,各个实施例之间的技术方案可以相互结合,但是必须是以本领域普通技术人员能够实现为基础,当技术方案的结合出现相互矛盾或无法实现时应当认为这种技术方案的结合不存在,也不在本申请要求的保护范围之内。In addition, the technical solutions between the various embodiments can be combined with each other, but it must be based on what can be achieved by a person of ordinary skill in the art. When the combination of technical solutions is contradictory or cannot be achieved, it should be considered that such a combination of technical solutions does not exist. , Not within the scope of protection required by this application.
如图1-3所示,提出本申请一优选实施例的一种电火花磨削复合加工工具,包括砂轮基体1、磨削段5和电极段2,砂轮基体1为圆盘状,磨削段5与电极段2交替设置于砂轮基体1的外缘端面。本实施例中电极段2电火花加工损耗速率小于磨削段5金属基的电火花加工损耗速率,能够在电火花磨削复合粗加工阶段防止磨粒3快速脱落,提高了超硬与难磨削材料的粗加工的效率。在进行精加工时,将低能量电火花放电间隙δ2小于磨粒3出刃高度,能够提高超硬与难磨削材料的精加工工件6的表面质量。As shown in Figures 1-3, a preferred embodiment of the present application is proposed as an EDM composite machining tool, which includes a grinding wheel base 1, a grinding section 5 and an electrode section 2. The grinding wheel base 1 is disc-shaped and is ground The segments 5 and the electrode segments 2 are alternately arranged on the outer edge end surface of the grinding wheel base 1. In this embodiment, the EDM loss rate of electrode section 2 is less than the metal-based EDM loss rate of grinding section 5, which can prevent abrasive particles 3 from falling off quickly during the composite rough machining stage of EDM grinding, and improve the super hard and hard-to-wear The efficiency of rough machining of cutting materials. In the finishing process, the low-energy electric spark discharge gap δ2 is smaller than the height of the abrasive particles 3, which can improve the surface quality of the finishing workpiece 6 made of super-hard and difficult-to-grind materials.
在本实施例中,磨削段5和电极段2的弧长相等,磨削段5由磨粒3和金属基粘接剂混合烧结而成。电极段2由电极材料粉末烧结而成,电极材料的电火花加工损耗率应小于金属基4的电火花加工损耗率。使用形成高能量放电的工艺参数对工件6进行粗加工,使得高能量电火花放电间隙δ1大于等于磨粒出刃高度h,实现高效率的高能电火花旋转加工,同时砂轮磨削段5完成出刃。电极段2电火花加工损耗速率略小于磨削段5金属基4电火花加工损耗速率,因此电极段2直径略大于磨削段5金属基4部分的直径,达到电极段2对磨削段5起保护作用的效果,避免了磨粒3的快速脱落。在其他实施例中,磨削段和电极段弧长度均可调整。In this embodiment, the arc lengths of the grinding section 5 and the electrode section 2 are equal, and the grinding section 5 is formed by mixing and sintering abrasive particles 3 and a metal-based adhesive. The electrode section 2 is sintered from electrode material powder, and the EDM loss rate of the electrode material should be less than the EDM loss rate of the metal base 4. The workpiece 6 is rough-machined using the process parameters that form the high-energy discharge, so that the high-energy EDM discharge gap δ1 is greater than or equal to the height h of the abrasive grains. The EDM loss rate of electrode section 2 is slightly lower than that of grinding section 5 metal base 4 EDM, so the diameter of electrode section 2 is slightly larger than the diameter of the metal base 4 of grinding section 5, reaching electrode section 2 to grinding section 5 The protective effect prevents the abrasive particles 3 from falling off quickly. In other embodiments, the arc length of the grinding section and the electrode section can be adjusted.
砂轮基体1由不锈钢、黄铜或易车铁制成。本实施例中砂轮基体1材料包括不锈钢、黄铜、易车铁,易车铁为易切削钢,主要通过加入硫或铅等元素加强其金属切削性,机床切削性能好。砂轮基体1的外径范围为40mm-200mm,砂轮基体1的内径范围为12mm-35mm,砂轮基体1的厚度范围为0.5mm-20mm。The grinding wheel base body 1 is made of stainless steel, brass or easy-turning iron. In this embodiment, the material of the grinding wheel substrate 1 includes stainless steel, brass, and free-turning iron. The free-turning iron is free-cutting steel. The metal machinability is enhanced by adding elements such as sulfur or lead, and the machine tool cutting performance is good. The outer diameter of the grinding wheel base 1 ranges from 40 mm to 200 mm, the inner diameter of the grinding wheel base 1 ranges from 12 mm to 35 mm, and the thickness of the grinding wheel base 1 ranges from 0.5 mm to 20 mm.
电极段2由纯铜粉末、纯钨粉末、黄铜粉末或白铜粉末制成。铜具有高的导电性、导热性、耐磨蚀性能及优良的工艺性能,粒度范围为1μm~20μm。The electrode section 2 is made of pure copper powder, pure tungsten powder, brass powder or cupronickel powder. Copper has high electrical conductivity, thermal conductivity, abrasion resistance and excellent process performance, with a particle size range of 1μm~20μm.
磨粒3由金刚石粒料、碳化硼粒料或碳化硅磨料制成。金刚石、碳化硼和碳化硅具有密度低、强度大、高温稳定性以及化学稳定性好的特点,粒度范围为0.1μm~10μm。The abrasive particles 3 are made of diamond particles, boron carbide particles or silicon carbide abrasive materials. Diamond, boron carbide and silicon carbide have the characteristics of low density, high strength, high temperature stability and good chemical stability, and the particle size ranges from 0.1μm to 10μm.
金属粘结剂由铜、锡混合粉末和或铜锡合金粉末制成。其中铜、锡混合粉末的粒度范围为1μm~20μm,铜锡合金粉末的粒度范围为25μm~50μm。The metal binder is made of copper, tin mixed powder and or copper-tin alloy powder. The particle size range of copper and tin mixed powder is 1μm-20μm, and the particle size range of copper-tin alloy powder is 25μm-50μm.
在本实施例中,磨削段5和电极段2需要分别烧结到砂轮基体1圆周上交替连接组成砂轮工具,磨削段5和电极段2弧长度均可调整。其中磨削段5由金属基粘接剂和磨粒均匀混合后烧结而成;电极段2由电极材料粉末烧结而成,电极材料的电火花加工损耗率应小于金属基粘接剂的电火花加工损耗率。In this embodiment, the grinding section 5 and the electrode section 2 need to be respectively sintered to the circumference of the grinding wheel base 1 and alternately connected to form a grinding wheel tool. The arc length of the grinding section 5 and the electrode section 2 can be adjusted. The grinding section 5 is made by uniformly mixing the metal-based adhesive and abrasive particles and then sintered; the electrode section 2 is made by sintering the electrode material powder, and the EDM loss rate of the electrode material should be less than that of the metal-based adhesive. Processing loss rate.
具体实施例1:Specific embodiment 1:
在本具体实施例中,一种电火花磨削复合加工工具,该电火花磨削复合加工工具具有环形阵列形式,该砂轮工具分别由高性能电极材料组成的电极段2和磨削段5相间分布构成。本实施例中的砂轮基体1为圆盘状,磨削段5与电极段2交替设置于砂轮基体1的外缘端面,磨削段5由磨粒3和金属基粘结剂混合烧结而成,电极段2的电火花加工损耗速率小于金属基4的电火花加工损耗率,将砂轮基体1放入第一模具中并在外圆空白处填充铜粉进行烧结,获得含有环形阵列电极段2的砂轮基体;再将含有环形阵列电极段2的砂轮基体放入第二模具中,在外圆空白处填充铜粉、锡粉和金刚石磨料的混合粉末,再次进行烧结处理,获得含有电极段2和磨削段5交替连接形成砂轮工具外圆的完整砂轮,使用这种特殊砂轮工具,在一次装夹范围内即可完成超硬与难磨削材料的高效率粗加工和高质量精加工。粗加工时,使用可形成高能量放电的工艺参数,使得高能量电火花放电间隙δ1大于磨粒出刃高度h,实现高效率的高能电火花旋转加工,同时砂轮磨削段5完成出刃;精加工时,使用可形成低能量放电的工艺参数,使得低能量电火花放电间隙δ2小于等于磨粒出刃高度h,实现高精度的电火花磨削旋转加工。In this specific embodiment, an EDM grinding composite machining tool, the EDM grinding composite machining tool has an annular array form, and the grinding wheel tool is composed of an electrode section 2 and a grinding section 5 composed of high-performance electrode materials. Distribution composition. The grinding wheel base 1 in this embodiment is disc-shaped, and the grinding section 5 and the electrode section 2 are alternately arranged on the outer edge end surface of the grinding wheel base 1. The grinding section 5 is formed by mixing and sintering abrasive particles 3 and a metal-based binder , The EDM loss rate of the electrode section 2 is less than that of the metal base 4. Put the grinding wheel base 1 into the first mold and fill the blank of the outer circle with copper powder for sintering to obtain a ring-shaped array electrode section 2 Grinding wheel base body; then put the grinding wheel base body containing the annular array electrode segment 2 into the second mold, fill the mixed powder of copper powder, tin powder and diamond abrasive in the blank of the outer circle, and perform sintering again to obtain the electrode segment 2 and the grinding wheel. The cutting segments 5 are alternately connected to form a complete grinding wheel of the outer circle of the grinding wheel tool. With this special grinding wheel tool, high-efficiency rough machining and high-quality finishing of super-hard and difficult-to-grind materials can be completed within a clamping range. During rough machining, use process parameters that can form high-energy discharge, so that the high-energy EDM discharge gap δ1 is greater than the height h of the abrasive grain, to achieve high-efficiency and high-energy EDM rotary machining, and the grinding wheel grinding section 5 completes the edge; When using process parameters that can form a low-energy discharge, the low-energy EDM discharge gap δ2 is less than or equal to the height of the abrasive grain h, and high-precision EDM rotary machining is realized.
具体实施例2:Specific embodiment 2:
在本具体实施例中,一种电火花磨削复合加工工具,该电火花磨削复合加工工具具有环形阵列形式,该砂轮工具分别由高性能电极材料组成的电极段2和磨削段5相间分布构成。本实施例中的砂轮基体1为圆盘状,磨削段5与电极段2交替设置于砂轮基体1的外缘端面,磨削段5由磨粒3和金属基粘结剂混合制成,电极段2的电火花加工损耗速率小于磨削段5金属基4的损耗率,本实施例中的电极段由铜、锡混合粉末和铜锡合金粉末混合烧结而成,再将含有环形阵列电极段2的砂轮基体放入第二模具中,在外圆空白处填充碳化硼粒料和铜锡合金粉末混合粉末,本实施例中在20mm厚的易车铁上加工出砂轮基体1,使用这种特殊砂轮工具,在一次装夹范围内即可完成超硬与难磨削材料的高效率粗加工和高质量精加工。粗加工时,使用可形成高能量放电的工艺参数,使得高能量电火花放电间隙δ1大于磨粒出刃高度h,实现高效率的高能电火花旋转加工,同时砂轮磨削段5完成出刃;精加工时,使用可形成低能量放电的工艺参数,使得低能量电火花放电间隙δ2小于等于磨粒出刃高度h,实现高精度的电火花磨削旋转加工。In this specific embodiment, an EDM grinding composite machining tool, the EDM grinding composite machining tool has an annular array form, and the grinding wheel tool is composed of an electrode section 2 and a grinding section 5 composed of high-performance electrode materials. Distribution composition. The grinding wheel base 1 in this embodiment is disc-shaped. The grinding section 5 and the electrode section 2 are alternately arranged on the outer edge end surface of the grinding wheel base 1. The grinding section 5 is made by mixing abrasive particles 3 and a metal-based binder. The EDM loss rate of the electrode section 2 is less than the loss rate of the metal base 4 of the grinding section 5. The electrode section in this embodiment is mixed and sintered with copper, tin mixed powder and copper-tin alloy powder, and then contains the ring array electrode The grinding wheel matrix of section 2 is placed in the second mold, and the mixed powder of boron carbide granules and copper-tin alloy powder is filled in the outer circle. In this embodiment, the grinding wheel matrix 1 is processed on a 20mm thick free-wheeling iron. The special grinding wheel tool can complete the high-efficiency rough machining and high-quality finishing of super-hard and difficult-to-grind materials within a single clamping range. During rough machining, use process parameters that can form high-energy discharge, so that the high-energy EDM discharge gap δ1 is greater than the height h of the abrasive grain, to achieve high-efficiency and high-energy EDM rotary machining, and the grinding wheel grinding section 5 completes the edge; When using process parameters that can form a low-energy discharge, the low-energy EDM discharge gap δ2 is less than or equal to the height of the abrasive grain h, and high-precision EDM rotary machining is realized.
具体实施例3:Specific embodiment 3:
本实施例基于上述具体实施例1提出一种电火花磨削复合加工工具的制备方法,包括步骤:This embodiment proposes a method for preparing an EDM grinding composite machining tool based on the above specific embodiment 1, including the steps:
采用电火花线切割工艺在厚度为15mm的不锈钢板上加工出砂轮基体1;不锈钢具有较强的耐磨性能。The grinding wheel base 1 is processed on a stainless steel plate with a thickness of 15mm by using the wire EDM process; stainless steel has strong wear resistance.
将砂轮基体1放入第一模具中填充铜粉末进行烧结获得含有电极段2的砂轮基体1;Put the grinding wheel base 1 into the first mold and fill with copper powder for sintering to obtain the grinding wheel base 1 containing the electrode segment 2;
将含有电极段2的砂轮基体1放入第二模具中填充铜、锡混合粉末和金刚石磨粒混合均匀后进行烧结,获得含有电极段2和磨削段5交替连接形成砂轮工具外圆的完整砂轮。Put the grinding wheel base 1 containing the electrode segment 2 into the second mold and fill it with copper, tin mixed powder and diamond abrasive grains, and then sinter it to obtain the complete outer circle of the grinding wheel tool containing electrode segments 2 and grinding segments 5 alternately connected Grinding wheel.
具体实施例4:Specific embodiment 4:
本实施例基于上述具体实施例2提出的一种电火花磨削复合加工工具的制备方法,包括步骤:This embodiment is based on the method for preparing an EDM grinding composite machining tool proposed in the foregoing specific embodiment 2, and includes the steps:
采用电火花线切割工艺在厚度为10mm的易车铁上加工出砂轮基体1;易车铁具有较强的耐磨性能。The grinding wheel base 1 is machined on the easy-turning iron with a thickness of 10mm by using the electric discharge wire cutting process; the easy-turning iron has strong wear resistance.
将砂轮基体1放入第一模具中填充纯钨粉末进行烧结,获得含有电极段2的砂轮基体1。The grinding wheel base 1 is put into the first mold and filled with pure tungsten powder for sintering to obtain the grinding wheel base 1 containing the electrode segment 2.
将含有电极段2的砂轮基体1放入第二模具中填充碳化硼粒料和铜锡合金粉末混合均匀后进行烧结,获得含有电极段2和磨削段5交替连接形成砂轮工具外圆的第一砂轮。Put the grinding wheel base body 1 containing the electrode segment 2 into the second mold and fill it with boron carbide granules and copper-tin alloy powder, and then sinter it to obtain the second electrode segment 2 and the grinding segment 5 alternately connected to form the outer circle of the grinding wheel tool One grinding wheel.
如图3-5所示,提出本申请一优选实施例的一种电火花磨削复合加工方法,包括步骤:As shown in Figures 3-5, a preferred embodiment of the present application is proposed as an EDM composite machining method, including the steps:
将第一砂轮和工件6分别安装在磨床上,第一砂轮接脉冲电源负极,工件6接脉冲电源正极;Install the first grinding wheel and the workpiece 6 on the grinding machine respectively, the first grinding wheel is connected to the negative pole of the pulse power supply, and the workpiece 6 is connected to the positive pole of the pulse power supply;
在本实施例中,工件6材料为钛合金、硬质合金、碳化硅或导电陶瓷。In this embodiment, the material of the workpiece 6 is titanium alloy, hard alloy, silicon carbide or conductive ceramic.
将第一砂轮调整到第一高度,本实施例中的第一高度是指将高能量电火花放电间隙设为δ1;使用高能量放电的工艺参数对工件6进行粗加工;使得电极段2放电间隙δ1大于等于磨粒出刃高度h,实现高效率的高能电火花旋转加工,同时砂轮磨削段5完成出刃。电极段2电火花加工损耗速率小于磨削段5金属基电火花加工损耗速率,使得电极段2直径大于磨削段5金属基直径,之后电极段2对磨削段5起到保护作用,防止磨粒3快速脱落。Adjust the first grinding wheel to the first height. The first height in this embodiment refers to setting the high-energy electric spark discharge gap to δ1; using the high-energy discharge process parameters to perform rough machining on the workpiece 6; making the electrode segment 2 discharge The gap δ1 is greater than or equal to the height h of the abrasive grain exiting edge, which realizes high-efficiency and high-energy EDM rotary machining, and the grinding wheel grinding section 5 completes the edge extraction. The EDM loss rate of electrode section 2 is less than the metal base EDM loss rate of grinding section 5, so that the diameter of electrode section 2 is greater than the metal base diameter of grinding section 5. After that, electrode section 2 protects the grinding section 5 and prevents The abrasive particles 3 fall off quickly.
将第一砂轮调整到第二高度,本实施例中的第二高度是指将低能量电火花放电间隙设为δ2;使用低能量放电的工艺参数对工件6进行精加工,使得电极段2放电间隙小于等于磨粒出刃高度h,实现高精度的电火花磨削旋转加工,得到高品质加工面的工件6。Adjust the first grinding wheel to the second height. The second height in this embodiment refers to setting the low-energy electric spark discharge gap to δ2; use the low-energy discharge process parameters to finish machining the workpiece 6 so that the electrode segment 2 discharges The gap is less than or equal to the height h of the abrasive grain exiting edge, which realizes high-precision electric discharge grinding and rotation processing, and obtains a workpiece 6 with a high-quality processing surface.
在本实施例中,高能量放电的工艺参数指加工电压为90-120V,脉宽为10-50μs;低能量放电的工艺参数指加工电压为30-50V,脉宽为1-10μs。In this embodiment, the process parameters of high-energy discharge refer to a processing voltage of 90-120V and a pulse width of 10-50 μs; the process parameters of low-energy discharge refer to a processing voltage of 30-50 V and a pulse width of 1-10 μs.
使用这种特殊砂轮工具,在一次装夹范围内即可完成超硬与难磨削材料的高效率粗加工和高质量精加工。粗加工时,使用可形成高能量放电的工艺参数,使得高能量电火花放电间隙δ1大于磨粒出刃高度h,实现高效率的高能电火花旋转加工,同时砂轮磨削段5完成出刃;精加工时,使用可形成低能量放电的工艺参数,使得低能量电火花放电间隙δ2小于等于磨粒出刃高度h,实现高精度的电火花磨削旋转加工。Using this special grinding wheel tool, high-efficiency roughing and high-quality finishing of super-hard and difficult-to-grind materials can be completed within a single clamping range. During rough machining, use process parameters that can form high-energy discharge, so that the high-energy EDM discharge gap δ1 is greater than the height h of the abrasive grain, to achieve high-efficiency and high-energy EDM rotary machining, and the grinding wheel grinding section 5 completes the edge; When using process parameters that can form a low-energy discharge, the low-energy EDM discharge gap δ2 is less than or equal to the height of the abrasive grain h, and high-precision EDM rotary machining is realized.
具体实施例5:Specific embodiment 5:
本实施例基于上述具体实施例1提出的一种电火花磨削复合加工方法,包括步骤:This embodiment is based on the electric spark grinding composite machining method proposed in the above specific embodiment 1, and includes the steps:
将第一砂轮和工件6分别安装在磨床上,第一砂轮接脉冲电源负极,工件6接脉冲电源正极;本实施例中的工件6材料为导电陶瓷。The first grinding wheel and the workpiece 6 are respectively installed on the grinder, the first grinding wheel is connected to the negative electrode of the pulse power supply, and the workpiece 6 is connected to the positive electrode of the pulse power supply; the material of the workpiece 6 in this embodiment is conductive ceramic.
将第一砂轮调整到粗加工深度所需要第一高度;使用高能量放电的工艺参数对工件6进行粗加工;使得高能量电火花放电间隙δ1大于等于磨粒出刃高度h,实现高效率的高能电火花旋转加工,同时砂轮磨削段5完成出刃。电极段2电火花加工损耗速率小于磨削段5金属基电火花加工损耗速率,使得电极段2直径大于磨削段5金属基直径,之后电极段2对磨削段5起到保护作用,防止磨粒3快速脱落。Adjust the first grinding wheel to the first height required for the rough machining depth; use high-energy discharge process parameters to rough-machine the workpiece 6; make the high-energy EDM discharge gap δ1 greater than or equal to the height of the abrasive grain h, achieving high efficiency and high energy At the same time, the grinding wheel grinding section 5 completes the cutting edge. The EDM loss rate of electrode section 2 is less than the metal base EDM loss rate of grinding section 5, so that the diameter of electrode section 2 is greater than the metal base diameter of grinding section 5. After that, electrode section 2 protects the grinding section 5 and prevents The abrasive particles 3 fall off quickly.
将第一砂轮调整到精加工深度所需要的第二高度;使用低能量放电的工艺参数对工件6进行精加工,使得低能量电火花放电间隙δ2小于等于磨粒出刃高度h,实现高精度的电火花磨削旋转加工,得到高品质加工面的工件6。Adjust the first grinding wheel to the second height required for the finishing depth; use the low-energy discharge process parameters to finish the workpiece 6 so that the low-energy electric spark discharge gap δ2 is less than or equal to the height of the abrasive grain h, achieving high precision Electric spark grinding and rotating processing, to obtain high-quality work piece 6.
在本实施例中,高能量放电的工艺参数指加工电压为120V,脉宽为50μs;低能量放电的工艺参数指加工电压为50V,脉宽为10μs。In this embodiment, the process parameters of high-energy discharge refer to a processing voltage of 120V and a pulse width of 50 μs; the process parameters of low-energy discharge refer to a processing voltage of 50 V and a pulse width of 10 μs.
具体实施例6:Specific embodiment 6:
本实施例基于上述具体实施例2提出的一种电火花磨削复合加工方法,包括步骤:This embodiment is based on the above-mentioned specific embodiment 2 and proposed an electric spark grinding composite machining method, including the steps:
将第一砂轮和工件6分别安装在磨床上,第一砂轮接脉冲电源负极,工件6接脉冲电源正极;本实施例中的工件6材料为碳化硅。碳化硅又名金刚砂,是用石英砂、石油焦(或煤焦)、木屑(生产绿色碳化硅时需要加食盐)等原料通过电阻炉高温冶炼而成。碳化硅在大自然也存在罕见的矿物。碳化硅又称碳硅石。在当代C、N、B等非氧化物高技术耐火原料中,碳化硅为应用最广泛、最经济的一种,可以称为金钢砂或耐火砂。碳化硅化学性能稳定、导热系数高、热膨胀系数小、耐磨性能好。The first grinding wheel and the workpiece 6 are respectively installed on the grinding machine, the first grinding wheel is connected to the negative electrode of the pulse power supply, and the workpiece 6 is connected to the positive electrode of the pulse power supply; the material of the workpiece 6 in this embodiment is silicon carbide. Silicon carbide, also known as emery, is made by smelting raw materials such as quartz sand, petroleum coke (or coal coke), wood chips (salt is needed to produce green silicon carbide) through a high temperature resistance furnace. Silicon carbide is also a rare mineral in nature. Silicon carbide is also called moissanite. Among the non-oxide high-tech refractory raw materials such as C, N, and B, silicon carbide is the most widely used and most economical one, and it can be called gold steel grit or refractory grit. Silicon carbide has stable chemical properties, high thermal conductivity, low thermal expansion coefficient and good wear resistance.
将第一砂轮调整到粗加工深度所需要第一高度;使用高能量放电的工艺参数对工件6进行粗加工;使得高能量电火花放电间隙δ1大于等于磨粒出刃高度h,实现高效率的高能电火花旋转加工,同时砂轮磨削段5完成出刃。电极段2电火花加工损耗速率小于磨削段5金属基电火花加工损耗速率,使得电极段2直径大于磨削段5金属基直径,之后电极段2对磨削段5起到保护作用,防止磨粒3快速脱落。Adjust the first grinding wheel to the first height required for the rough machining depth; use high-energy discharge process parameters to rough-machine the workpiece 6; make the high-energy EDM discharge gap δ1 greater than or equal to the height of the abrasive grain h, achieving high efficiency and high energy At the same time, the grinding wheel grinding section 5 completes the cutting edge. The EDM loss rate of electrode section 2 is less than the metal base EDM loss rate of grinding section 5, so that the diameter of electrode section 2 is greater than the metal base diameter of grinding section 5. After that, electrode section 2 protects the grinding section 5 and prevents The abrasive particles 3 fall off quickly.
将第一砂轮调整到精加工深度所需要的第二高度;使用低能量放电的工艺参数对工件6进行精加工,使得低能量电火花放电间隙δ2小于等于磨粒出刃高度h,实现高精度的电火花磨削旋转加工,得到高品质加工面的工件6。Adjust the first grinding wheel to the second height required for the finishing depth; use the low-energy discharge process parameters to finish the workpiece 6 so that the low-energy electric spark discharge gap δ2 is less than or equal to the height of the abrasive grain h, achieving high precision Electric spark grinding and rotating processing, to obtain high-quality work piece 6.
在本实施例中,高能量放电的工艺参数指加工电压为100V,脉宽为40μs;低能量放电的工艺参数指加工电压为40V,脉宽为5μs。In this embodiment, the process parameters of high energy discharge refer to a processing voltage of 100V and a pulse width of 40 μs; the process parameters of low energy discharge refer to a processing voltage of 40 V and a pulse width of 5 μs.
本申请的电火花磨削复合加工工具,在一次装夹范围内即可完成超硬与难磨削材料的高效率粗加工和高质量精加工。粗加工时,使用可形成高能量放电的工艺参数,使得高能量电火花放电间隙δ1大于磨粒出刃高度h,实现高效率的高能电火花旋转加工,同时砂轮磨削段完成出刃;精加工时,使用可形成低能量放电的工艺参数,使得低能量电火花放电间隙δ2小于等于磨粒出刃高度h,实现高精度的电火花磨削旋转加工。本实施例中的一种电火花磨削复合加工工具、制备及其加工方法,通过设置高性能电极段与磨削段相间分布的砂轮工具,在一次装夹范围内即可完成超硬与难磨削材料的高效率粗加工和高质量精加工。The electric spark grinding composite machining tool of the present application can complete high-efficiency rough machining and high-quality finishing of super-hard and difficult-to-grind materials within a clamping range. During rough machining, use process parameters that can form high-energy discharge, so that the high-energy EDM discharge gap δ1 is greater than the height h of the abrasive grain, to achieve high-efficiency and high-energy EDM rotary machining, and the grinding section of the grinding wheel completes the edge; , Using process parameters that can form low-energy discharge, make the low-energy EDM discharge gap δ2 less than or equal to the height of the abrasive grains, h, and realize high-precision EDM rotary machining. In this embodiment, an electric spark grinding composite machining tool, preparation and machining method thereof, by setting a high-performance electrode segment and a grinding wheel tool distributed alternately with the grinding segment, can complete the super-hard and difficult High efficiency rough machining and high quality finishing of grinding materials.
Claims (10)
- 一种电火花磨削复合加工工具,其特征在于,包括砂轮基体、磨削段和电极段,所述砂轮基体为圆盘状,所述磨削段与所述电极段交替设置于所述砂轮基体的外缘端面。An electric spark grinding composite machining tool, which is characterized by comprising a grinding wheel base, a grinding section and an electrode section, the grinding wheel base is in the shape of a disc, and the grinding section and the electrode section are alternately arranged on the grinding wheel The outer edge of the base.
- 根据权利要求1所述的电火花磨削复合加工工具,其特征在于,所述磨削段由磨粒和金属基粘接剂均匀混合后烧结而成,所述电极段电火花加工损耗速率小于所述磨削段金属基的电火花加工损耗速率。The EDM composite machining tool according to claim 1, wherein the grinding section is formed by uniformly mixing abrasive particles and a metal-based adhesive and then sintered, and the EDM loss rate of the electrode section is less than The EDM loss rate of the metal base of the grinding section.
- 根据权利要求2所述的电火花磨削复合加工工具,其特征在于,所述金属基粘接剂由铜、锡混合粉末和或铜锡合金粉末制成。The electric spark grinding composite machining tool according to claim 2, wherein the metal-based adhesive is made of copper, tin mixed powder, or copper-tin alloy powder.
- 一种电火花磨削复合加工工具的制备方法,其特征在于,包括步骤:A preparation method of an electric spark grinding composite machining tool is characterized in that it comprises the following steps:在预设厚度的基材上加工出砂轮基体;The grinding wheel base is processed on the base material of preset thickness;将所述砂轮基体放入第一模具中填充第一预设材料进行烧结,获得含有电极段的砂轮基体;Putting the grinding wheel base into a first mold and filling it with a first preset material for sintering, to obtain a grinding wheel base containing electrode segments;将所述含有电极段的砂轮基体放入第二模具中填充第二预设材料进行烧结,获得第一砂轮。The grinding wheel base body containing the electrode segments is put into a second mold and filled with a second preset material for sintering to obtain a first grinding wheel.
- 根据权利要求4所述的电火花磨削复合加工工具的制备方法,其特征在于,所述在预设厚度的基材上加工出砂轮基体的步骤,包括:The method for preparing an EDM grinding composite machining tool according to claim 4, wherein the step of processing a grinding wheel matrix on a substrate with a predetermined thickness comprises:在厚度为0.5mm-20mm的不锈钢、黄铜或易车铁上加工出砂轮基体。The grinding wheel matrix is processed on stainless steel, brass or easy-turning iron with a thickness of 0.5mm-20mm.
- 根据权利要求4所述的电火花磨削复合加工工具的制备方法,其特征在于,所述将所述砂轮基体放入第一模具中填充第一预设材料进行烧结,获得含有电极段的砂轮基体的步骤,包括:The method for preparing an EDM composite machining tool according to claim 4, wherein the grinding wheel matrix is put into a first mold and filled with a first preset material for sintering to obtain a grinding wheel containing electrode segments The steps of the matrix include:所述将所述砂轮基体放入第一模具中填充纯铜粉末、纯钨粉末、黄铜粉末或白铜粉末进行烧结,获得含有电极段的砂轮基体。The grinding wheel matrix is put into a first mold and filled with pure copper powder, pure tungsten powder, brass powder or cupronickel powder for sintering to obtain a grinding wheel matrix containing electrode segments.
- 根据权利要求4所述的电火花磨削复合加工工具的制备方法,其特征在于,所述将所述含有电极段的砂轮基体放入第二模具中填充第二预设材料进行烧结,获得第一砂轮的步骤,包括:The method for preparing an EDM composite machining tool according to claim 4, wherein the grinding wheel matrix containing the electrode segments is placed in a second mold and filled with a second preset material for sintering to obtain the first The steps of a grinding wheel include:将所述含有电极段的砂轮基体放入第二模具中填充金属基粘结剂与磨料的混合物进行烧结,获得第一砂轮。The grinding wheel base body containing the electrode segments is put into a second mold and filled with a mixture of a metal-based binder and an abrasive for sintering to obtain a first grinding wheel.
- 一种电火花磨削复合加工方法,其特征在于,包括:An electric spark grinding compound machining method, which is characterized in that it comprises:将第一砂轮和工件分别安装在磨床上,所述第一砂轮接脉冲电源负极,所述工件接脉冲电源正极;Install the first grinding wheel and the workpiece on the grinding machine respectively, the first grinding wheel is connected to the negative pole of the pulse power supply, and the workpiece is connected to the positive pole of the pulse power supply;将所述第一砂轮调整到第一高度;使用高能量放电的工艺参数对所述工件进行粗加工;Adjust the first grinding wheel to a first height; use high-energy discharge process parameters to rough machine the workpiece;将所述第一砂轮调整到第二高度;使用低能量放电的工艺参数对所述工件进行精加工,得到高品质加工面的工件。Adjust the first grinding wheel to a second height; use low-energy discharge process parameters to finish machining the workpiece to obtain a workpiece with a high-quality machining surface.
- 根据权利要求8所述的电火花磨削复合加工方法,其特征在于,所述高能量放电的工艺参数指加工电压为90-120V,脉宽为10-50μs。The EDM composite machining method according to claim 8, wherein the process parameters of the high-energy discharge are a machining voltage of 90-120V and a pulse width of 10-50μs.
- 根据权利要求8所述的电火花磨削复合加工方法,其特征在于,所述低能量放电的工艺参数指加工电压为30-50V,脉宽为1-10μs。The EDM composite machining method according to claim 8, wherein the process parameters of the low-energy discharge are a machining voltage of 30-50V and a pulse width of 1-10μs.
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