铜钨合金工具电极电火花多次切割工艺研究

Study on multi-cutting process of copper tungsten alloy tool electrode by WEDM

  • 摘要: 铜钨合金工具电极在电火花成形加工中具有极佳的加工性能,电火花线切割多次切割是工具电极制造的重要技术方法。通过响应曲面法研究了第1次切割脉冲宽度、峰值电流、伺服电压对切割速度的影响规律,并优化得到了最大切割速度下的组合工艺参数,在此基础上又进行了不同切割次数对工具电极加工质量影响的研究。研究结果表明:第1次切割脉冲宽度50 μs、峰值电流12 A及伺服电压12 V,切割速度最大为25.08 mm2/min。1次切割的尺寸误差在10 μm以内,切割表面粗糙度Ra2.582 μm;2次切割的尺寸误差在5 μm以内,切割表面粗糙度Ra1.177 μm;3次切割的尺寸误差在3 μm以内,切割表面粗糙度Ra0.732 μm。随着切割次数的增加,切割表面沉积的碳元素增多,有助于提高电极的低损耗性能。

     

    Abstract: Copper tungsten alloy tool electrode has excellent processing performance in EDM, and WEDM multiple cutting is an important technical method for tool electrode manufacturing. The influence of the first cutting pulse width, peak current and servo voltage on the cutting speed was studied by response surface method, and the combined process parameters under the maximum cutting speed were optimized. On this basis, the influence of different cutting times on the machining quality of tool electrode was studied. The results showed that when the first cutting pulse width is 50 μs, the peak current is 12 A and the servo voltage is 12 V, the maximum cutting speed is 25.08 mm2/min. Moreover, the dimension error of one cutting is less than 10 μm and the surface roughness is Ra 2.582 μm. The dimension error of secondary cutting is less than 5 μm, the surface roughness is Ra 1.177 μm. The dimension error of three times cutting is less than 3 μm, the surface roughness is Ra 0.732 μm. With the increase of cutting times, the carbon deposited on the cutting surface increases, which helps to improve the low loss performance of the electrode.

     

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