CN103537768A - Wire electrode for WEDM-LS electrical discharge machining and preparation method of wire electrode - Google Patents
Wire electrode for WEDM-LS electrical discharge machining and preparation method of wire electrode Download PDFInfo
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Abstract
The invention discloses a wire electrode for WEDM-LS electrical discharge machining and a preparation method of the wire electrode. The wire electrode comprises a core portion, a transition layer, a covering layer and an oxide layer. The core portion is made of brass alloy or red copper. The transition layer covers the outer layer of the core portion and comprises a continuous portion and an interruption portion formed by beta-phase pinchbeck alloy protruding from the continuous portion. The covering layer is formed by the interruption portion formed by the beta-phase pinchbeck alloy, cracked gamma-phase pinchbeck alloy inlaid on the interruption and gaps. The inevitable oxide layer is formed on the surface of the covering layer. The zinc content at the joint between the core portion and the transition layer and the zinc content at the joint between the transition layer and the covering layer are distributed in a linear increase mode. According to the wire electrode with the special tissue structure, the gasification capacity of zinc can be adjusted in the cutting process, cutting efficiency and cutting accuracy are promoted, cost is saved to the largest degree and machining quality is improved.
Description
Technical field
The present invention relates to wire electrode and preparation method thereof for a kind of slow wire feeding spark discharge processing (electro discharge machining).
Background technology
Slow wire feeding spark discharge processing method is a kind of precision optical machinery processing method developing rapidly in recent years.By the former Russian scholar La Zhalianke Mr. and Mrs, nineteen forty-three study invention the earliest, afterwards, along with the improvement of the pulse power and control system, develop rapidly.Spark machined is to utilize the special process method of the galvanic action ablation conductive material producing while being immersed in two interpolar pulsed discharge in working solution, claims again electric discharge processing or galvanic corrosion processing, the English EDM(Electrical Discharge Machining that is called for short).
According to the form of tool-electrode and and workpiece between the feature of relative motion, spark machined mode can be divided into five classes: Wire-cut Electrical Discharge Machining; Spark-erosion sinking processing; Electric spark grinding; Electric spark conjugation revolution processing; The processing of other kinds such as aperture processing, mint-mark, surface alloying, surface peening.And Wire-cut Electrical Discharge Machining is according to the difference of wire travelling speed, can be divided into: fast wire winding spark machined, middle wire spark machined, slow wire feeding spark machined, what the present invention mainly set forth is last a kind of Wire-cut Electrical Discharge Machining.
The development of slow wire feeding spark machined, be unable to do without the synchronized development of wire electrode technology, the design concept of popular slow wire feeding lathe is to design according to the operating characteristic of wire electrode in the world now, and the breakthrough of wire electrode technology tends to drive the innovation of wire cutting machine design.From the copper free wire of initial use, cut to present recombination line and cut, the development experience of slow wire feeding cutting from inefficient, low quality to high efficiency, high-quality, automation, a specialized very long course of producing.The line cutting technology development of China is progressively to introduce on the basis that absorbs advanced foreign technology and growing up, from fast wire winding the earliest, wire be worked into now gradually in the slow wire feeding processing of generally using, experienced a development course from low to high.As previously mentioned, the development of wire electrode technology has determined the developing direction of cutting technique, how to research and develop wire electrode, is first appreciated that the principle of spark machined here.
Electrical spark working man-hour, a utmost point bonding tool electrode of the pulse power, another utmost point connects piece pole, and the two poles of the earth are all immersed in the liquid medium (conventional kerosene or mineral oil or deionized water, the silk thread cutting processing of being careful is commonly used deionized water) with certain insulativity.Tool-electrode is controlled by auto-feed adjusting device, maintains a very little discharging gap (0.01～0.05mm) with assurance instrument and workpiece when the normal process.When pulse voltage is added between the two poles of the earth, just the liquid medium of interpolar closest approach under prevailing condition is punctured, form discharge channel.Because the sectional area of passage is very little, discharge time is extremely short, causes energy height to concentrate (10～107W/mm), and the TRANSIENT HIGH TEMPERATURE that region of discharge produces is enough to make even evaporation of material fusing, so that forms galvano-cautery small rut one by one.After pulsed discharge finishes for the first time, through very short interval time, second pulse is again in another interpolar closest approach disruptive discharge, circulate down to the high-frequency of so going round and beginning again, tool-electrode is constantly to workpiece feeding, the shape of its walking is finally just replicated on workpiece, forms needed machining shape.Meanwhile, the sub-fraction of gross energy is also discharged on tool-electrode, thereby causes tool loss.From physical angle analysis, the general basic principle of line cutting processing is: under normal circumstances, workpiece connects the positive pole of the pulse power, wire electrode connects the negative pole of the pulse power, electric discharge adds man-hour, free cation and electronics accumulate in field, form very soon a conductive channel being ionized, in this stage, free cation moves to wire electrode direction, free anion moves to workpiece direction, this movement causes occurring to collide many times between particle, form an ion plasma, and be elevated to very soon the high temperature of 8000 to 12000 degree, at two some materials of conductive surface instant melting, workpiece and wire electrode surface are all gone out numerous irregular pitting by galvano-cautery, simultaneously, vaporization due to wire electrode and electrolyte, form a bubble, and its pressure rule rises until very high, then current interruptions, temperature reduces suddenly, cause bubble implosion, the power producing dishes out the material of fusing by the irregular pitting of galvano-cautery, then the material being corroded regelation in electrolyte becomes little spheroid, and by electrolyte, drained that (slow wire feeding electric discharge adds man-hour, electrolyte is generally deionized water).
Continuous progress along with materials processing technology and Machining Technology, wire electrode has experienced the use conversion from basis brass wire electrode to coating electrode silk, the multi-layer composite electrode silk of even studying now, the research of these coating electrode silks is arisen at the historic moment according to the principle of electric discharge processing invariably, the coating of heterogeneity, coating surface is artificial adds the crackle of shape in a subtle way, and disclosed technology shows that the existence of this micro-shape crackle is favourable to cutting.Because this micro-shape crackle has the function of cooling and chip removal that absorbs water concurrently, thereby can improve cutting speed.
For machining, pursuing precision is the current major subjects facing, for production management, consideration be how to raise the efficiency, and for slow wire feeding electric discharge processing method, in the time of raising speed, may reduce the precision of processing, and when improving machining accuracy, will inevitably reduce working (machining) efficiency, therefore, wire electrode of the present invention is when not affecting machining accuracy, improves to greatest extent process velocity.
Set forth the concrete technology status of the domestic and international wire electrode that uses below:
One, basis brass wire electrode: kind electrode silk is copper zinc bianry alloy, because be subject to zinc in brass containing quantitative limitation, its cutting speed has been subject to restriction, and along with zinc in brass content increases, its cutting speed also has little lifting, but its hoisting velocity is limited.Kind electrode silk is generally used by present domestic domestic consumer, and fall copper powder, break, is the universal phenomenon of meeting in the use procedure of kind electrode silk.Because zinc is containing quantitative limitation, its cutting accuracy is affected too simultaneously.
Two, zinc-plated wire electrode: core is basis brass, outside plating one deck zinc, due to the gasification of zinc in cutting process, the electric discharge meeting of kind electrode silk is more stable, and cutting surfaces can be more sliding than basis brass mercerising.The manufacture country of comparative maturity is mainly distributed in Europe in the world, and at present domestic also have indivedual producers to produce, but kind electrode silk in use common problem be dry linting problem, manufacturer faces equally both at home and abroad.On the other hand, kind electrode silk is because surperficial pure zinc forms, and the gasification rate of pure zinc has than comparatively fast, and the zinc on top layer can consume rapidly in cutting process, so the cutting speed of kind electrode silk is equally also restricted.The similar patent documentation of kind electrode silk has Chinese patent CN1139032A.
Three, velocity profile coating electrode silk: core is basis brass, coating is ormolu, it is thicker that the coating of the common zinc-plated wire electrode of Thickness Ratio is wanted.The speed of this coating electrode silk is faster than the cutting speed of common zinc-plated wire electrode, is suitable for high efficiency processing, because kind electrode silk top layer is ormolu, the content of zinc can not be too high, so cutting accuracy is also restricted.
Four, β type wire electrode: research discovery, surface has the wire electrode of even craterlet (crackle) can improve the discharge effect of wire electrode, arises at the historic moment, and has just produced the wire electrode of this porous surface structure.Diffusion annealing type wire electrode core is oxygen-free copper or brass alloys, and by diffusion annealing at skin bag layer of copper kirsite, wherein the ratio of copper and zinc is close to 1:1, because core is oxygen-free copper or brass alloys, top layer is the loose structure that adopts diffusion annealing to form, its wire electrode material surface be organized as β phase, therefore the common call of kind electrode silk is β type wire electrode, as everyone knows, under normal temperature, the zinc content of β phase is less than 50%.Because zinc is containing quantitative limitation, during electric discharge, the interval of spark discharge can increase, so on microcosmic, the hole, hole of galvano-cautery can be larger, is reacted to macroscopic view upper, and the cutting fineness of this silk is not high.
Five, γ type wire electrode: research is found, textura epidermoidea is the wire electrode of γ phase, surface cutting accuracy can be higher, because the zinc content of γ phase is in 60% left and right, the common call of kind electrode silk is γ type wire electrode, this structure is many at wire electrode zinc content, during spark discharge, interval can be smaller, and on microcosmic, the hole, hole of galvano-cautery can be less, be reacted to macroscopic view upper, the cutting fineness of this silk can be higher.On the other hand, because γ mutually in zinc content higher, and the galvano-cautery speed of zinc can be than comparatively fast, zinc can consume rapidly in cutting process, therefore the cutting speed of kind electrode silk is also restricted, and the similar patent documentation of kind electrode silk is US Patent No. 5945010.
Six, compound facies pattern wire electrode: β phase and γ phase are contained in kind electrode silk surface simultaneously, therefore be again compound facies pattern wire electrode, kind electrode silk is in conjunction with the advantage of β type wire electrode and γ type wire electrode wire electrode, cutting speed and cutting accuracy are improved simultaneously, kind electrode silk only has a few industrially developed country to produce now in the world, because will produce the mixture of β phase and γ phase simultaneously, therefore its manufacturing cost can be higher, kind electrode silk is because the reason of use cost now, almost do not have producer to use, the similar patent documentation of kind electrode silk has Chinese patent CN102756188A, CN101115580B, CN102239024A.
Summary of the invention
The above-mentioned deficiency that the present invention is directed to prior art, provides a kind of low cost of manufacture, discharge stability during cutting, the slow wire feeding spark discharge processing wire electrode that cutting accuracy is high.
In order to solve the problems of the technologies described above, the technical solution used in the present invention is: a kind of slow wire feeding spark discharge processing wire electrode, and this wire electrode comprises the core of being made by brass alloys or red copper (copper simple substance or title fine copper); Be coated on the outer field transition zone of core; Transition zone comprises continuous portion and protrudes from the discontinuities of the β phase ormolu formation of continuous portion; Cover layer, the discontinuities that described cover layer consists of β phase ormolu, is embedded in discontinuities broken γ phase ormolu and space (crackle) and forms; The inevitable oxide layer forming in cover surface (surface that comprises discontinuities, the γ phase ormolu that is embedded in fragmentation in discontinuities and space formation that β phase ormolu forms).
The above-mentioned tectal γ phase ormolu of the present invention, β phase ormolu and space (crackle) be the cover layer of alternative arrangement complete successively.
Space described in cover layer of the present invention (crackle) is 5-40% to the coverage rate of the continuous portion of transition zone circumferencial direction (being on continuous portion outer circumference surface).
The ormolu of γ phase described in cover layer of the present invention is 5-50% to the coverage rate of the continuous portion of transition zone circumferencial direction (being on continuous portion outer circumference surface).
As preferably, the continuous portion of transition zone of the present invention and cover layer and the inevitably radially maximum aggregate thickness of oxide layer (from transition zone inner surface to oxide layer outer surface maximum ga(u)ge radially) are less than 30% of wire electrode diameter.
As further preferably, the continuous portion of transition zone of the present invention and cover layer and the inevitably radially maximum aggregate thickness of oxide layer (from transition zone inner surface to oxide layer outer surface maximum ga(u)ge radially) are the 5-15% of wire electrode diameter (D0).
As preferably, the radial thickness (radially maximum ga(u)ge) that is embedded in γ phase ormolu broken in discontinuities of the present invention is less than 10% of wire electrode diameter.
As further preferred, the radial thickness (radially maximum ga(u)ge) that the present invention is embedded in the broken γ phase ormolu in discontinuities is the 0.5-5% of wire electrode diameter (D0).
As preferably, the thickness of oxide layer of the present invention is less than 0.5% of wire electrode diameter.
The brass alloys composition of formation core of the present invention consists of: copper 58wt%-95wt%, zinc 5.0wt%-42.0wt%, and inevitable impurity element.
The diameter of wire electrode of the present invention is 0.07-0.35mm.
In the scope of the 0.1-5% that the particle size that is embedded in the broken γ phase ormolu on transition zone of the present invention is wire electrode diameter.
The chemical composition of the inevitable oxide layer of the present invention is the oxide layer that cupric oxide, cuprous oxide and zinc oxide form.
The radial thickness of the inevitable oxide layer of the present invention is less than 0.5% of wire electrode diameter (D0).
Transitional region zinc content between layers of the present invention is linear to be increased; The zinc content that is specially the same continuous portion of described core transition region is linear to be increased, and portion is linearity increase with the zinc content of discontinuities transition region continuously.
The present invention also provides a kind of preparation method of above-mentioned wire electrode, and preparation process comprises:
(1) provide the body core of being made by red copper or brass alloys;
(2) utilize electroless plating method, spraying process or hot dipping method (electroless plating method, spraying process or hot dipping method are industry conventional method) to cover pure zinc layer on described body core, to form female blank;
(3) annealing:
(3.1) female blank step (2) Suo Shu is carried out to ladder diffusion annealing; First the selection of ladder diffusion annealing temperature and time is to be at 60-250 ℃, to make the pure zinc of body core and top layer mutually diffuse to form just cover layer, time 1-25 hour in low-temperature zone; Then continuing to be warming up to high temperature section is 250.1-750 ℃ of temperature, and is incubated 1-35 hour, makes body core and cover layer continue mutually to diffuse to form just transition zone; This process can be inevitably in the first oxide layer of the just outer formation of cover layer;
Or
(3.2) with the temperature of 250-750 ℃, female blank of described step (2) is carried out to two sections of online annealing; First the first paragraph temperature of two sections of online annealing way is selected is to make to make the pure zinc of body core and top layer mutually to diffuse to form just cover layer at lower temperature, and temperature is 250 ℃-450 ℃; Second segment is high temperature section, and it is to make body core and cover layer continue mutually to diffuse to form just transition zone that temperature is selected, and it is 451 ℃-750 ℃ that the temperature of high temperature section is selected interval; This process can be inevitably in the first oxide layer of the just outer formation of cover layer;
(4) finished product that female blank step (3) being made carries out large working modulus stretches, to reach final product diameter, the first transition zone of drawing process is drawn into the transition zone of wire electrode, and make just cover layer drawing crack fragmentation form cover layer, just oxide layer is drawn into the oxide layer of wire electrode, obtains wire electrode;
(5) wire electrode step (4) being formed carries out stress relief annealing.
In the above-mentioned two kinds of method for annealing of the present invention, after female blank anneal, also will carry out coolingly, the pH value that is chosen as of cooling medium is less than the 7 acid cooling mediums (such as hydrochloric acid, sulfuric acid etc.) that are greater than 1; The selection of pickling cooling medium is to make the thickness of final oxide layer be less than 0.5% of wire electrode diameter (D0).
The stress relief annealing of finishing operation of the present invention is to carry out with the stretching of large working modulus simultaneously, and stress relief annealing is to carry out in the annealing liquid of steady temperature, and this liquid also has passivation to the surface of wire electrode; Stress relief annealing temperature is being less than 650 ℃, and the duration is less than in 1 hour and completes.
The ladder diffusion annealing of above-mentioned steps of the present invention (3.1) is carried out in air or in oxidizing atmosphere; The selection of temperature retention time is under the prerequisite allowing in industrial production, fully generates that length is selected diffusion time of γ phase and β phase time.
Described large working modulus refers to that working modulus is greater than 70% and be less than 99%.Described working modulus refers to that the initial basal area before processing deducts the ratio of basal area after processing and initial basal area.
The process annealing stage of the ladder diffusion annealing of step of the present invention (3.1) is in order mutually to diffuse to form γ phase, and preferred low temperature is 100 ℃-215 ℃.
The high annealing stage of the ladder diffusion annealing of step of the present invention (3.1) is to make the first transition zone (γ phase) and the body core that generate mutually diffuse to form transition zone (β phase), and preferred high temperature is 350 ℃-650 ℃.
Two sections of online annealing of step of the present invention (3.2), first paragraph annealing distance is 1.0-3.5m, second stage annealing distance is 4.0-10.0m; The annealing speed of two sections of online annealing is 5-550 m/min.
Advantage of the present invention and beneficial effect:
1. wire electrode of the present invention is the advantage of comprehensive utilization β type wire electrode and γ type wire electrode, and make the γ on top layer pass through mutually the extruding of mould and fully broken by large working modulus, and on the surface of wire electrode, form uniform crackle (hole, hole), the β of transition zone can be extended along with stretching mutually, the wire electrode of this structure, can in the situation that not affecting machining accuracy, improve to greatest extent process velocity, thereby save manufacturing cost.
The present invention by the high low temperature of the online annealing of stepped annealing, two sections is set, the length of temperature retention time are produced γ phase and β phase.Because during diffusion annealing, α in β phase the inside is flexible mutually, therefore the brass mixture of β phase composition is also flexible, therefore when the stretching of large working modulus, the transition zone that β accounts for main component brass compositions of mixtures is mutually not by drawing crack, along with core extends and elongated simultaneously, the design of this structure makes product when final use, not produce the situation that the impacts such as dry linting, scaling are used.
3. the present invention fully extends by large working modulus the β that generates on female base and not broken mutually, makes to cover the γ that β goes up mutually fully broken mutually, and the broken particulate producing is inlaid into β phase, and between broken particulate, produces hole (crackle), hole; By large working modulus, make material production work hardening, and the degree of materials processing sclerosis can be adjusted by the height of copper content and the size of working modulus, this large working modulus adopts a plurality of moulds to complete on a machine in production application simultaneously on the other hand, can reduce greatly human and material resources, save manufacturing cost.
4. the present invention anneals in oxidisability or air atmosphere, during annealing, can produce inevitable oxide layer, and the chemical composition of oxide layer is cupric oxide, cuprous oxide, zinc oxide; And fact proved that this oxidation mixture is attached to the surface of wire electrode, to cutting, be favourable, favourable object is that this oxidation mixture has self-lubricating function, and this self-lubricating function is when cutting, while making the third wheel of line process slow wire feeding cutting machine, the surface of protection third wheel is not scratched wheel; Discharge stability when this oxidation mixture also contributes to improve cutting simultaneously, improves cutting accuracy; Moreover the oxide of this mixing contributes to protect product not produce in use dry linting, scaling.
5. of the present invention cooling: in pH value, to be less than 7 and to carry out in being greater than 1 acid cooling medium, because being oxide layer, blocked up oxidation mixture can make the pick-up current on wire electrode top layer reduce, under low current cut capacity, be not easy cutting, and acid cooling medium can neutralize a part of oxide layer, the thickness of preferred oxide layer is to be less than 0.1% of line of cut diameter, control the temperature of cooling medium well simultaneously, can form on wire electrode surface passivating film, and this passivating film has and prevents that wire electrode from continuing the effect of oxidation again.
6. the stress relief annealing that the present invention adopts can stabilized electrodes wire material performance, make the conductance of wire electrode promote simultaneously, and stress relief annealing of the present invention is to carry out with the processing of large working modulus simultaneously, it is to carry out in the annealing liquid of steady temperature that the cooling of continuous annealing process drawn by this company, and this liquid also has passivation to the surface of wire electrode.
7. wire electrode of the present invention is to produce under to the operating mode of environment pollution useless, is conducive to sustainable development; For achieving the above object, according to one of them aspect of the present invention, being provided for female base of wire electrode of the present invention, is to have a core material, and three kinds of cover layers form, as accompanying drawing 2.
8. the β that the present invention is inlaid into the mutually identical adjacent β of γ of the inside forms a kind of new alloy-layer mutually, wherein between γ phase and β phase, there is space, between broken γ phase, also there is space simultaneously, thereby space can intake and accelerate cooling velocity, simultaneously all right collection of debris, therefore, this space is favourable to the lifting of cutting efficiency and surface quality.
Accompanying drawing explanation
Fig. 1 is the cross sectional representation of wire electrode of the present invention;
Fig. 2 is the cross sectional representation of annealing stepmother blank;
Fig. 3 is female blank of the present invention metallograph in kind;
Fig. 4 is the cross section in kind metallograph of wire electrode 1 of the present invention;
Fig. 5 is that the cross section in kind metallographic of wire electrode 1 of the present invention amplifies picture;
Fig. 6 is that the outward appearance in kind of wire electrode 1 of the present invention is amplified picture;
Fig. 7 is the local structure for amplifying schematic diagram (not indicating oxide layer 5) of wire electrode of the present invention;
Fig. 8 is the female blank zinc of the present invention content structural representation;
Fig. 9 is final products wire electrode zinc content structural representation of the present invention.
The specific embodiment
Below by embodiment, the present invention is described in further detail, but the present invention is not only confined to following examples.
" β phase " of the present invention refers to that zinc content is at the ormolu of 44wt% to 50wt%, as everyone knows, at normal temperatures, " β ' phase " is orderly, at high temperature in subcooled process, can occur unordered to orderly conversion, but this conversion is not completely, be also under normal temperature, β ' mutually the inside also has β phase, in order to express conveniently, unification of the present invention is expressed as β phase ormolu.
Described γ of the present invention is that zinc content is at the ormolu of 60wt% left and right mutually.Disclosed technology shows, the ormolu of 60wt% left and right, and β phase is also contained in the inside, and in order to express conveniently, unification of the present invention is expressed as γ phase ormolu.
Described α of the present invention is less than the ormolu of 38wt% mutually for zinc content, α has moulding and can extend.
1. as shown in accompanying drawing 1 and accompanying drawing 7, slow wire feeding spark discharge processing of the present invention comprises with wire electrode the core 2 of being made by brass alloys or red copper; Be coated on the outer field transition zone 3 of core 2; Transition zone 3 comprises continuous portion 3.1 and protrudes from the discontinuities 3b of the β phase ormolu formation of continuous portion; Cover layer 4, the discontinuities 3b that described cover layer 4 consists of β phase ormolu and space 3c(crackle, hole, hole) form; The inevitable oxide layer 5 forming on cover layer 4 surfaces.
Shown in Fig. 2: the first transition zone 7 of female blank of the present invention is the ormolu that β accounts for main component mutually, and first transition zone 7 is with also containing α phase in the constituent of the interface of body core 6, and first cover layer 8 is γ phase ormolus.
The discontinuities 3b that cover layer 4 of the present invention consists of β phase ormolu, the γ phase that is embedded in the upper broken γ phase ormolu 3a of discontinuities 3b, embedding, space 3c(crackle or hole, hole) alternately form.
In order to prove that the manufacture method of wire electrode structure of the present invention and wire electrode is favourable, by the following examples, proved.
Embodiment 1
1, manufacture the wire electrode A that wire electrode diameter D0 of the present invention is 0.25mm, it is the core 2 that 80wt% brass alloys are made that this wire electrode includes copper content, this core 2 is coated with the transition zone 3 that zinc content is the β phase ormolu composition of 47wt%, transition zone 3 comprise be continuous shape continuous portion 3.1 and and protrude from the discontinuities 3b that the β phase ormolu of continuous portion forms, and have γ phase ormolu that the zinc content in the continuous portion 3.1 that is embedded in transition zone 3 is 60wt% and hole, hole and β phase composition that the zinc content that exposes is 47wt%;
2, for this reason, adopting spraying process is that diameter is that the copper content of 1.2mm is that 80wt% brass wire (body core 6) electroplating thickness is the zinc coating of 11 μ m;
3, the silk after step 2 spraying is well carried out to ladder diffusion annealing in annealing furnace, low-temperature zone annealing temperature is 160 ℃, and temperature retention time 3 hours forms just cover layer 8; The annealing temperature of high temperature section is 380 ℃, and temperature retention time is 3 hours; Make body core 6 and cover layer 8 continue mutually to diffuse to form just transition zone 7; This process can be inevitably in the first oxide layer 9 of the just outer formation of cover layer 7;
4, in stove, the line base of the wire electrode of step 4 gained is cooled to after 70 ℃, then taking out and putting into pH value is that 5 cooling medium (example hydrochloric acid) continuation is cooling;
5, in cooling medium, only need to place the time in 10 seconds, take out, clean with water rinse;
6, adopting Lian Lalian to move back the line base of equipment after to step 5 stepped annealing carries out the stretching of large working modulus and stress relief annealing (workpiece is being less than under the condition of 650 ℃, annealing speed 850-1500 m/min, annealing is apart from 0.5-10 rice, then in annealing liquid, (annealing liquid also can claim to burn stewed oil, it is a general saying in industry that stewed oil is burnt in annealing, on market, can buy, as such in the multidrawDG that Germany produces; Domestic also have a lot, as FX128 etc.) in carry out post processing, annealing liquid temperature is 25-100 degree), and batch take-up, the specification of stretching gained finished product is 0.25mm, the tensile strength of this wire electrode that test is surveyed is 905N/mm
2;
7, same any basis brass wire electrode on the market of wire electrode A is cut to contrast;
8, the FA10SADVANCE2009 machine that the slow wire feeding cutting machine that test is used is manufactured for Mitsubishi;
9, experimental condition is as follows: the workpiece size of test cutting is 40*6*6(0.5*3 groove); Workpiece material: SKD11; Device parameter: NM; Processing number of times: one repaiies four; Cooked mode: soaking type; The tension parameters of equipment is adjusted into and is applicable to 900N/mm
2wire electrode; Nozzle is pressed against on workpiece.The cutting effect of wire electrode that records two types is as shown in table 1 below:
Table 1 is implemented the cutting effect of the wire electrode of 1 two types
| Wire electrode classification | Processing total time | The first cutter speed | The first cutter time | Workpiece roughness |
| Basis brass silk | 25 minutes 34 seconds | 3.1-3.4mm/min | 10 minutes 17 seconds | Ra=0.351 |
| Wire electrode A | 21 minutes 15 seconds | 3.5-3.9mm/min | 8 minutes 55 seconds | Ra=0.355 |
10, as can be seen from Table 1, in the essentially identical situation of workpiece surface roughness, to cut total time, calculate, the cutting efficiency of wire electrode prepared by the present embodiment has promoted 20.28%.
1, manufacture the wire electrode B that wire electrode diameter D0 of the present invention is 0.25mm, it is the core 2 that 63wt% brass alloys are made that this wire electrode includes copper content, this core is coated with the transition zone 3 that zinc content is 47% β phase composition, and has γ phase that the zinc content that is embedded on transition zone 3 is 60wt% and hole, hole and β phase composition that the zinc content that exposes is 47wt%;
2, for this reason, adopting hot dipping method is that diameter is that the copper content of 1.1mm is that 63wt% brass wire (body core 6) electroplating thickness is the zinc coating of 10 μ m;
3, the female blank after plating is stretched to 1.0mm;
4, female blank of 1.0mm is carried out to two sections of on-line continuous diffusion annealings, first paragraph section annealing temperature is 420 ℃, and annealing distance is 3 meters, makes the pure zinc in body core 6 and top layer mutually diffuse to form just cover layer 8; Second stage annealing temperature is 550 ℃, and annealing distance is 5.2 meters, makes body core 6 and just cover layer 8 continuation mutually diffuse to form just transition zone 7; The speed of above-mentioned two sections of online annealing is 145 ms/min; This process can be inevitably in the first oxide layer 9 of the just outer formation of cover layer;
5, the cooling fluid pH value of online annealing is 5;
6, the female blank after batching is clean with water rinse;
7, adopt the Lian Lalian equipment that moves back to carry out stretching and the stress relief annealing of large working modulus to the line base after annealing, and batch take-up, the specification of stretching gained finished product is 0.25mm, and the tensile strength of this wire electrode that test is surveyed is 1010N/mm
2; 8, wire electrode B is cut to contrast with γ type wire electrode;
9, the FA10SADVANCE2009 machine that the slow wire feeding cutting machine that test is used is manufactured for Mitsubishi;
10, experimental condition is as follows: the workpiece size of test cutting is 40*6*6(0.5*3 groove); Workpiece material: SKD11; Device parameter: NM; Processing number of times: one repaiies four; Cooked mode: soaking type; The tension parameters of equipment is adjusted into and is applicable to 900N/mm
2wire electrode; Nozzle is pressed against on workpiece.The cutting effect of wire electrode that records two types is as shown in table 2 below:
The cutting effect of the wire electrode that table 2 embodiment is 2 two types
| Wire electrode classification | Processing total time | The first cutter speed | The first cutter time | Workpiece roughness |
| γ type wire electrode | 23 minutes 12 seconds | 3.4-3.7mm/ |
9 minutes 37 seconds | Ra=0.375 |
| Wire electrode B | 21 minutes 28 seconds | 3.5-3.9mm/ |
9 minutes 07 second | Ra=0.367 |
11, as can be seen from Table 2, in the essentially identical situation of workpiece surface roughness, to cut total time, calculate, cutting efficiency has promoted 9.17%.
1, manufacture the wire electrode C that wire electrode diameter D0 of the present invention is 0.25mm, it is the core 2 that 63wt% brass alloys are made that this wire electrode includes copper content, this core is coated with the transition zone 3 that zinc content is the β phase composition of 47wt%, and has γ phase that the zinc content that is embedded on transition zone 3 is 60wt% and hole, hole and β phase composition that the zinc content that exposes is 47wt%;
2, for this reason, adopting galvanoplastic is that diameter is that the copper content of 1.0mm is that 63wt% brass wire electroplating thickness is the zinc coating of 7 μ m;
3, the female blank after plating is stretched to 0.95mm;
4, the line base of 0.95mm is carried out to ladder diffusion annealing in stove, low-temperature zone annealing temperature is 175 ℃, temperature retention time 2 hours, and the annealing temperature of high temperature section is 420 ℃, temperature retention time is 2.5 hours;
5, in stove, line base is cooled to after 70 ℃, puts into pH value and be 4.5 cooling medium and continue cooling;
6, in cooling medium, place the time in 10 seconds, take out, clean with water rinse;
7, adopt the Lian Lalian equipment that moves back to carry out stretching and the stress relief annealing of large working modulus to the line base after annealing, and batch take-up, the specification of stretching gained finished product is 0.25mm, and the tensile strength of this wire electrode that test is surveyed is 1035N/mm
2;
8, wire electrode C is cut to contrast with β type wire electrode;
9, the FA10SADVANCE2009 machine that the slow wire feeding cutting machine that test is used is manufactured for Mitsubishi;
10, experimental condition is as follows: the workpiece size of test cutting is 40*6*6(0.5*3 groove); Workpiece material: SKD11; Device parameter: NM; Processing number of times: one repaiies four; Cooked mode: soaking type; The tension parameters of equipment is adjusted into and is applicable to 900N/mm
2wire electrode; Nozzle is pressed against on workpiece.The cutting effect of wire electrode that records two types is as shown in table 3 below:
The cutting effect of the wire electrode that table 3 embodiment is 3 two types
| Wire electrode classification | Processing total time | The first cutter speed | The first cutter time | Workpiece roughness |
| β type wire electrode | 22 minutes 12 seconds | 3.4-3.9mm/ |
9 minutes 15 seconds | Ra=0.385 |
| Wire electrode C | 21 minutes 07 second | 3.6-4.1mm/min | 8 minutes 47 seconds | Ra=0.361 |
11, as can be seen from Table 3, in the situation that workpiece surface roughness has lifting, to cut total time, calculate, cutting efficiency has promoted 5.16%.
1, manufacture the wire electrode D that wire electrode diameter D0 of the present invention is 0.25mm, it is the core 2 that 63wt% brass alloys are made that this wire electrode includes copper content, this core is coated with the transition zone 3 that zinc content is the β phase composition of 47wt%, and has γ phase that the zinc content that is embedded on transition zone 3 is 60wt% and hole, hole and β phase composition that the zinc content that exposes is 47wt%;
2, for this reason, adopting galvanoplastic is that diameter is that the copper content of 0.9mm is that 63% brass wire electroplating thickness is the zinc coating of 7 μ m;
3,0.9 line base is carried out to ladder diffusion annealing in stove, low-temperature zone annealing temperature is 175 ℃, temperature retention time 2 hours, and the annealing temperature of high temperature section is 420 ℃, temperature retention time is 2.5 hours;
4, in stove, to line base is cold, go to after 70 ℃, put into pH value and be 5.5 cooling medium and continue cooling;
5, in cooling medium, place the time in 10 seconds, take out, clean with water rinse;
6, adopt the Lian Lalian equipment that moves back to carry out stretching and the stress relief annealing of large working modulus to the line base after annealing, and batch take-up, the specification of stretching gained finished product is 0.25mm, and the tensile strength of this wire electrode that test is surveyed is 920N/mm
2;
7, wire electrode D is cut to contrast with compound electrode silk;
8, the FA10SADVANCE2009 machine that the slow wire feeding cutting machine that test is used is manufactured for Mitsubishi;
9, experimental condition is as follows: the workpiece size of test cutting is 40*6*6(0.5*3 groove); Workpiece material: SKD11; Device parameter: NM; Processing number of times: one repaiies four; Cooked mode: soaking type; The tension parameters of equipment is adjusted into and is applicable to 900N/mm
2wire electrode; Nozzle is pressed against on workpiece.The cutting effect of wire electrode that records two types is as shown in table 4 below:
The cutting effect of the wire electrode that table 4 embodiment is 4 two types
| Wire electrode classification | Processing total time | The first cutter speed | The first cutter time | Workpiece roughness |
| Compound electrode silk | 21 minutes 45 seconds | 3.4-3.9mm/ |
9 minutes 01 second | Ra=0.379 |
| Wire electrode D | 21 minutes 28 seconds | 3.6-4.0mm/min | 8 minutes 47 seconds | Ra=0.381 |
10, as can be seen from Table 4, in the situation that workpiece surface roughness has lifting, to cut total time, calculate, the cutting efficiency of wire electrode D slightly promotes, but the manufacturing process of wire electrode A is more simple, and cost has superiority relatively.
Claims (10)
1. a slow wire feeding spark discharge processing wire electrode (1), is characterized in that: comprise the core (2) of being made by brass alloys or red copper; Be coated on the outer field transition zone of core (2) (3); Transition zone (3) comprises continuous portion (3.1) and protrudes from the discontinuities (3b) of the β phase ormolu formation of continuous portion; Cover layer (4), the discontinuities (3b) that described cover layer (4) consists of β phase ormolu, is embedded in upper broken γ phase ormolu (3a) and space (3c) of discontinuities (3b) and forms; The inevitable oxide layer (5) forming on cover layer (4) surface.
2. slow wire feeding spark discharge processing wire electrode according to claim 1, is characterized in that: the space (3c) described in cover layer (4) is 5-40% to the coverage rate of continuous portion (3.1) circumferencial direction of transition zone (3); γ phase ormolu (3a) broken in cover layer (4) is 5-50% to the coverage rate of continuous portion (3.1) circumferencial direction of transition zone (3);
The continuous portion (3.1) of described transition zone (3) and cover layer (4) and the inevitably radially maximum aggregate thickness of oxide layer (5) are less than 30% of wire electrode diameter;
The described radial thickness that is embedded in the upper broken γ phase ormolu (3a) of discontinuities (3b) is less than 10% of wire electrode diameter;
Described core (2) is linear increase with the zinc content of continuous portion (3.1) transition region, and the zinc content of the same discontinuities of portion (3.1) (3b) transition region is linear increase continuously;
The thickness of described oxide layer (5) is less than 0.5% of wire electrode diameter.
3. slow wire feeding spark discharge processing wire electrode according to claim 2, is characterized in that: the continuous portion (3.1) of described transition zone and cover layer (4) and the inevitably radially maximum aggregate thickness of oxide layer (5) are the 5-15% of wire electrode diameter.
4. slow wire feeding spark discharge processing wire electrode according to claim 2, is characterized in that: the described radial thickness that is embedded in the upper broken γ phase ormolu (3a) of discontinuities (3b) is the 0.5-5% of wire electrode diameter.
5. slow wire feeding spark discharge processing wire electrode according to claim 1, is characterized in that: the brass alloys composition of described formation core consists of: copper 58wt%-95wt%, zinc 5.0wt%-42.0wt%, and inevitable impurity element.
6. slow wire feeding spark discharge processing wire electrode according to claim 1, is characterized in that: the diameter of described wire electrode is 0.07-0.35mm.
7. slow wire feeding spark discharge processing wire electrode according to claim 1, is characterized in that: the chemical composition of described inevitable oxide layer is the oxide layer that cupric oxide, cuprous oxide and zinc oxide form.
8. slow wire feeding spark discharge is processed the preparation method with wire electrode, it is characterized in that: preparation process comprises:
(1) provide the body core (6) of being made by red copper or brass alloys;
(2) utilize electroless plating method, spraying process or hot dipping method at the upper pure zinc layer that covers of described body core (6), to form female blank;
(3) annealing:
(3.1) female blank step (2) Suo Shu is carried out to ladder diffusion annealing; First the selection of ladder diffusion annealing temperature and time is to be at 60-250 ℃, to make the pure zinc of body core and top layer mutually diffuse to form just cover layer (8), time 1-25 hour in low-temperature zone; Then continuing to be warming up to high temperature section is 250.1-750 ℃ of temperature, and is incubated 1-35 hour, makes body core (6) and cover layer (8) continue mutually to diffuse to form just transition zone (7); This process can be inevitably in the first oxide layer (9) of the just outer formation of cover layer;
Or
(3.2) with the temperature of 250-750 ℃, female blank of described step (2) is carried out to two sections of online annealing; First the first paragraph temperature of two sections of online annealing way is selected is to make to make the pure zinc of body core (6) and top layer mutually to diffuse to form just cover layer (8) at lower temperature, and temperature is 250 ℃-450 ℃; Second segment is high temperature section, and it is to make body core (6) and just cover layer (8) continuation mutually diffuse to form just transition zone (7) that temperature is selected, and it is 451 ℃-750 ℃ that the temperature of high temperature section is selected interval; This process can be inevitably in the first oxide layer (9) of the just outer formation of cover layer;
(4) finished product that female blank step (3) being made carries out large working modulus stretches, to reach final product diameter, the first transition zone of drawing process is drawn into the transition zone (3) of wire electrode, and make just cover layer drawing crack fragmentation form cover layer (4), just oxide layer (9) is drawn into the oxide layer (5) of wire electrode, obtains wire electrode;
(5) wire electrode step (4) being formed carries out stress relief annealing.
9. the preparation method of wire electrode for slow wire feeding spark discharge according to claim 8 processing, is characterized in that: described large working modulus refers to that working modulus is greater than 70% and be less than 99%; Described working modulus refers to that the initial basal area before processing deducts the ratio of basal area after processing and initial basal area.
10. the preparation method of wire electrode for slow wire feeding spark discharge processing according to claim 8, is characterized in that: the process annealing phase temperature of the ladder diffusion annealing of described step (3.1) is 100-175 ℃; High annealing phase temperature is 350-650 ℃; Two sections of online annealing of described step (3.2), first paragraph annealing distance is 1.0-3.5m, and second stage annealing distance is 4.0-10.0m, and the annealing speed of two sections of online annealing is 5-550 m/min.
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