CN111136353B - Electrolytic machining method for laminated tool electrode for electrolytic machining of micro-groove - Google Patents
Electrolytic machining method for laminated tool electrode for electrolytic machining of micro-groove Download PDFInfo
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- CN111136353B CN111136353B CN201911426130.0A CN201911426130A CN111136353B CN 111136353 B CN111136353 B CN 111136353B CN 201911426130 A CN201911426130 A CN 201911426130A CN 111136353 B CN111136353 B CN 111136353B
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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
- B23H3/00—Electrochemical machining, i.e. removing metal by passing current between an electrode and a workpiece in the presence of an electrolyte
- B23H3/04—Electrodes specially adapted therefor or their manufacture
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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
- B23H3/00—Electrochemical machining, i.e. removing metal by passing current between an electrode and a workpiece in the presence of an electrolyte
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Abstract
The invention discloses an electrolytic machining method of a laminated tool electrode for electrolytically machining a micro-fine groove, which comprises a plurality of conducting layers and insulating layers arranged on two sides of the conducting layers, wherein the conducting layers and the insulating layers are alternately arranged at intervals, the height of each conducting layer is less than that of each insulating layer, and the machining end faces of the conducting layers are parallel; the invention has the characteristics of good processing stability, high processing precision and high processing efficiency.
Description
Technical Field
The invention relates to the technical field of electrolytic machining, in particular to an electrolytic machining method of a laminated tool electrode for electrolytically machining a micro-groove.
Background
The surface texture is a structure with patterns of pits, grooves, bulges and the like with certain sizes and distribution on the surface of the friction pair through certain processing technology. The surface groove structure can contain particles in friction motion, so that the abrasion of the surface of the friction pair is reduced, and the service life of the friction pair is prolonged. In the aspect of heat dissipation, the groove structure can increase the heat exchange area and improve the heat exchange efficiency. Therefore, a technique for machining the fine groove appears to be of great importance.
The method for processing the micro-groove on the metal surface mainly comprises the technologies of micro-cutting processing, ultrasonic processing, micro-electric spark processing, LIGA technology, photoetching technology, surface shot blasting, laser surface micro-molding, electrolytic processing and the like. Due to the existence of acting force, a micro-cutting processing worker is very easy to deform a workpiece in the processing process, and meanwhile, the micro-groove usually has the defects of burrs and the like and needs secondary processing. The surfaces of materials such as micro electric discharge machining, laser machining and the like have heat affected zones which are easy to deform. The surface shot blasting technology has a powerful effect in the processing process, and stress exists around the groove to cause material deformation. The processing technologies such as the LIGA technology and the photoetching technology are complex, a special mask plate needs to be manufactured, the processing period of a workpiece is long, and the equipment investment is high. The electrochemical machining has the characteristic of removing the material in an ion form, has no effect in machining, and the machined material has a smooth surface and no heat influence area, and can be applied to machining of the micro-groove.
However, the existing electrolytic machining electrode has a complex structure, cannot be changed and controlled according to the specific structure of the surface texture to be formed, and has poor applicability.
In view of the above-mentioned drawbacks, the inventors of the present invention have finally obtained the present invention through a long period of research and practice.
Disclosure of Invention
In order to solve the technical defects, the technical scheme adopted by the invention is to provide a laminated tool electrode for electrolytically machining a micro-groove, which comprises a plurality of conducting layers and insulating layers arranged on two sides of the conducting layers, wherein the conducting layers and the insulating layers are alternately arranged at intervals, the height of each conducting layer is smaller than that of each insulating layer, and the machining end surfaces of the conducting layers are parallel.
Preferably, the thickness of the insulating layer is more than 250 [ mu ] m.
Preferably, the thickness of the conductive layer is between 20 micrometers and 8 millimeters.
Preferably, the electrochemical machining method using the laminated tool electrode for electrochemical machining of a micro groove includes the steps of:
s1, manufacturing the laminated tool electrode of the electrochemical machining micro-groove consisting of the conducting layer and the insulating layer;
s2, placing the workpiece below the laminated tool electrode of the electrochemical machining micro-groove and closely attaching the workpiece to the insulating layer of the laminated tool electrode of the electrochemical machining micro-groove;
s3, the workpiece and the conducting layer are respectively and electrically connected with the positive electrode and the negative electrode of a power supply;
s4, spraying an electrolyte solution to the machining region so that the electrolyte solution passes through the machining region formed between the conductive layer, the insulating layer and the workpiece;
and S5, switching on a power supply, and adjusting the electronic load to carry out electrolytic machining.
Preferably, the laminated tool electrode for electrolytically machining the micro-groove, which is composed of a plurality of conductive layers and a plurality of insulating layers, is placed above a flat metal electrode, a machining gap is arranged between the flat metal electrode and the laminated tool electrode for electrolytically machining the micro-groove, the conductive layer is used as an electrolytic anode, the flat metal electrode is used as an electrolytic cathode, electrolyte is sprayed to the machining gap, and a power supply is switched on to prepare the laminated tool electrode for electrolytically machining the micro-groove.
Preferably, when the laminated tool electrode for electrolytically machining the micro groove is prepared, the machining end face of the conductive layer is adjusted by an electronic load.
Compared with the prior art, the invention has the beneficial effects that: the invention has the characteristics of good processing stability, high processing precision and high processing efficiency.
Drawings
FIG. 1 is a schematic diagram of a laminated tool electrode for making the electrolytically machined micro-groove;
FIG. 2 is a schematic diagram of a stacked tool electrode with an electrolytically machined micro-groove having a uniform conductive layer height;
FIG. 3 is a schematic diagram of a stacked tool electrode for electrochemical machining of micro grooves with highly regular conductive layers;
FIG. 4 is a schematic diagram of a stacked tool electrode with an electro-chemically machined micro-groove having a highly irregular conductive layer;
FIG. 5 is a front view of the electrode electrochemical machining of a laminated tool for electrochemical machining of micro grooves according to example four;
FIG. 6 is a cross-sectional view A-A of FIG. 5;
FIG. 7 is a schematic diagram illustrating the electrochemical machining process of the electrode of the laminated tool for electrochemical machining of a micro groove according to the fourth embodiment;
FIG. 8 is a schematic view of a workpiece after electrolytic machining according to an example;
FIG. 9 is a front view of the electrode electrochemical machining of a laminated tool for electrochemical machining of micro grooves according to example V;
FIG. 10 is a cross-sectional view taken along line B-B of FIG. 9;
FIG. 11 is a schematic diagram illustrating the electrochemical machining process of the electrode of the laminated tool for electrochemical machining of a micro groove according to example V;
FIG. 12 is a schematic view of a workpiece after five electrolytic machining in accordance with an embodiment;
FIG. 13 is a front view of the electrode electrochemical machining of a laminated tool for electrochemical machining of micro grooves according to example six;
FIG. 14 is a cross-sectional view C-C of FIG. 13;
FIG. 15 is a schematic view illustrating the electrochemical machining process of the laminated tool electrode for electrochemical machining of a micro groove according to the sixth embodiment;
FIG. 16 is a schematic view of a workpiece after electrolytic machining according to an embodiment;
FIG. 17 is a graph of current density distribution for a stacked tool electrode of the described electrolytically machined micro-grooves with uniform conductive layer height at an electrical load voltage Δ U = 0.0V;
FIG. 18 is a graph of current density distribution for a stacked tool electrode of the described electrolytically machined micro-grooves with uniform conductive layer height at an electrical load voltage Δ U = 5.0V;
FIG. 19 is a graph of current density distribution for a stacked tool electrode of the described electrolytically machined micro-grooves with uniform conductive layer height at an electrical load voltage Δ U = 10.0V;
FIG. 20 is a graph of current density distribution for a stacked tool electrode of the described electrolytically machined micro-grooves with uniform conductive layer height at an electrical load voltage Δ U = 15.0V;
FIG. 21 is a graph of current density distribution for a stacked tool electrode for electrochemical machining of micro grooves as the electrical load voltage is progressively reduced;
FIG. 22 is a graph of current density distribution for a stacked tool electrode for electrochemical machining of micro-grooves with a first increase and a subsequent decrease in electrical load voltage;
FIG. 23 is a graph showing a current density distribution of a stacked tool electrode in which the electrolytically machined micro-grooves have irregular conductive layer heights;
fig. 24 is a current density distribution diagram of the surface of a workpiece when machined with the prepared laminated tool electrode.
The figures in the drawings represent:
1-an insulating layer; 2-a conductive layer; 3-a workpiece; 4-a power supply; 5-an electronic load; 6-plate metal electrode.
Detailed Description
The above and further features and advantages of the present invention are described in more detail below with reference to the accompanying drawings.
Example one
The laminated tool electrode for the electrochemical machining of the micro-groove comprises an insulating layer 1 and a conducting layer 2, wherein the conducting layer 2 and the insulating layer 1 are arranged at intervals alternately, the conducting layer 2 is electrolytically machined to a desired position, the laminated tool electrode for the electrochemical machining of the micro-groove is formed by alternately arranging and overlapping the insulating layers 1 and the conducting layers 2, a workpiece 3 is arranged below the laminated tool electrode for the electrochemical machining of the micro-groove, a machining end face of the conducting layer 2 corresponds to the workpiece 3, the laminated tool electrode for the electrochemical machining of the micro-groove is tightly attached to the workpiece 3, the workpiece 3 and the conducting layer 2 are respectively and electrically connected with a positive electrode and a negative electrode of a power supply 4, a machining area is arranged between the machining end face and the workpiece 3, and electrolyte a is arranged in the machining area. The conductive layers 2 are arranged in parallel.
Wherein the thickness of the insulating layer 1 is not less than 250 [ mu ] m.
The thickness of the conductive layer 2 is between tens of micrometers and several millimeters.
When the laminated tool electrode for the electrochemical machining of the micro groove is prepared, the position where the conductive layer 2 is machined is adjusted by the electronic load 5.
The height of the conducting layer 2 in the laminated tool electrode for the electrochemical machining of the micro-groove is smaller than that of the insulating layer 1, and the heights of all the conducting layers 2 are consistent.
The height of the conducting layer 2 in the laminated tool electrode for the electrochemical machining of the micro-groove is smaller than that of the insulating layer 1, and the height of the conducting layer 2 is regular, or the trend of increasing, or the trend of decreasing, or the height is regular.
In the laminated tool electrode for the electrochemical machining of the micro-groove, the height of the conducting layer 2 is smaller than that of the insulating layer 1, and the height of the conducting layer 2 is irregular.
The electrolytic machining method adopting the laminated tool electrode for electrolytically machining the micro-groove comprises the following specific steps:
s1, manufacturing the laminated tool electrode of the electrochemical machining micro-groove consisting of the conducting layer 2 and the insulating layer 1, wherein the conducting layer 2 and the insulating layer 1 are arranged at intervals;
s2, placing the workpiece 3 below the laminated tool electrode of the electrochemical machining micro-groove and closely attaching to the insulating layer 1 of the laminated tool electrode of the electrochemical machining micro-groove;
s3, the workpiece 3 and the conductive layer 2 are respectively electrically connected to the positive and negative electrodes of the power supply 4;
s4, spraying an electrolyte a to a machining region so that the electrolyte a passes through the machining region formed between the conductive layer 2, the insulating layer 1 and the workpiece 3;
and S5, switching on the power supply 4, and adjusting the electronic load 5 to carry out electrolytic machining.
The structural arrangement of the laminated tool electrode for the electrochemical machining of the micro-groove improves the machining stability, the height of the conducting layer is always smaller than that of the insulating layer, the insulating layer is tightly attached to the workpiece, the electrolyte flows through the conducting layer, the channel formed between the insulating layer and the workpiece is gentle, the channels are independent and do not interfere with each other, the removal of the electrolysis product and the update of the electrolyte are fast, and the machining stability is promoted.
The laminated tool electrode for the electrochemical machining of the micro-groove, which is provided with the conducting layer in the middle and the insulating layers on two sides, improves the machining precision, effectively inhibits the material removal of a non-machining area, and reduces the machining defects of secondary machining, stray corrosion and the like of the non-machining area. Therefore, high-precision processing with smaller groove width and lower stray corrosion is realized.
Example two
FIG. 1 is a schematic view of a laminated tool electrode for preparing the electrolytically machined micro-groove, as shown in FIG. 1; and placing the laminated tool electrode for the electrochemical machining micro-groove, which is composed of a plurality of layers of the conducting layers 2 and insulating layers 1, above a flat metal electrode 6, wherein a certain machining gap is kept between the flat metal electrode 6 and the laminated tool electrode for the electrochemical machining micro-groove, the conducting layers 2 are used as an electrolytic anode, the flat metal electrode 6 is used as an electrolytic cathode, an electrolyte a is sprayed to the machining gap, a power supply 4 is connected, and the laminated tool electrode for the electrochemical machining micro-groove is prepared.
EXAMPLE III
FIG. 2 is a schematic view of a laminated tool electrode for electrochemical machining of micro-grooves with uniform conductive layer height, as shown in FIGS. 2-4; FIG. 3 is a schematic diagram of a stacked tool electrode for electrochemical machining of micro grooves with highly regular conductive layers; FIG. 4 is a schematic diagram of the laminated tool electrode with the electrolytically machined micro-grooves having a highly irregular conductive layer.
If the power supply voltage applied between each of the conductive layers 2 and the flat metal electrode 6 is the same, the prepared stacked tool electrode in which the conductive layers 2 have the same height as the electrochemical machining micro grooves is manufactured.
If the size of the electronic load 5 is regularly adjusted so that the power supply voltage loaded between each conductive layer 2 and the flat metal electrode 6 is regular, the prepared laminated tool electrode of the electrochemical machining micro-groove with a certain regular height of each conductive layer 2 is obtained.
If the size of the electronic load 5 is irregularly adjusted so that the power supply voltage applied between each of the conductive layers 2 and the flat metal electrode 6 is irregular, the prepared laminated tool electrode in which each of the conductive layers 2 has irregular micro grooves for electrochemical machining is obtained.
Example four
FIG. 5 is a front view of the electrode electrochemical machining of a laminated tool for electrochemical machining of micro grooves according to example four, as shown in FIGS. 5 to 8; FIG. 6 is a cross-sectional view A-A of FIG. 5; FIG. 7 is a schematic diagram illustrating the electrochemical machining process of the electrode of the laminated tool for electrochemical machining of a micro groove according to the fourth embodiment; FIG. 8 is a schematic view of a workpiece after electrolytic machining according to the fourth embodiment.
In this embodiment, the stacked tool electrode for electrochemical machining of micro grooves with uniform conductive layer height is placed above the workpiece 3, the insulating layer 1 is tightly attached to the workpiece 3, an electrolyte channel is formed between the conductive layer 2, the insulating layer 1 and the workpiece 3, the workpiece 3 and the conductive layer 2 are respectively and electrically connected to the positive electrode and the negative electrode of the power supply 4, the power supply 4 is connected for electrochemical machining, and the expected structure is machined on the surface of the workpiece 3.
EXAMPLE five
FIG. 9 is a front view of the electrode electrochemical machining of a laminated tool for electrochemical machining of micro grooves according to example V, as shown in FIGS. 9 to 12; FIG. 10 is a cross-sectional view taken along line B-B of FIG. 9; FIG. 11 is a schematic diagram illustrating the electrochemical machining process of the electrode of the laminated tool for electrochemical machining of a micro groove according to example V; FIG. 12 is a schematic view of a workpiece after five electrolytic machining in example.
In this embodiment, the laminated tool electrode with a conductive layer having a certain regularity for electrochemical machining of micro grooves is placed above the workpiece 3, the insulating layer 1 is tightly attached to the workpiece 3, an electrolyte passage is formed between the conductive layer 2, the insulating layer 1 and the workpiece 3, the workpiece 3 and the conductive layer 2 are respectively and electrically connected to a positive electrode and a negative electrode of a power supply 4, the power supply 4 is switched on for electrochemical machining, and an expected structure is machined on the surface of the workpiece 3.
EXAMPLE six
FIG. 13 is a front view of the electrode electrochemical machining of a laminated tool for electrochemical machining of micro grooves according to example six, as shown in FIGS. 13 to 16; FIG. 14 is a cross-sectional view C-C of FIG. 13; FIG. 15 is a schematic view illustrating the electrochemical machining process of the laminated tool electrode for electrochemical machining of a micro groove according to the sixth embodiment; FIG. 16 is a schematic view of a workpiece after electrolytic machining according to the sixth embodiment.
In this embodiment, a laminated tool electrode with an irregular conductive layer for electrochemical machining of micro grooves is placed above the workpiece 3, the insulating layer 1 is tightly attached to the workpiece 3, an electrolyte channel is formed between the conductive layer 2, the insulating layer 1 and the workpiece 3, the workpiece 3 and the conductive layer 2 are respectively and electrically connected to a positive electrode and a negative electrode of a power source 4, the power source 4 is turned on for electrochemical machining, and a desired structure is machined on the surface of the workpiece 3.
The invention can meet the requirements of different types of micro grooves, the width of the groove can be realized by adjusting the thickness and the electrical parameters of the conducting layers in the laminated tool electrode, the adjusting range is wide, the distance between the grooves can be realized by adjusting the thickness of the insulating layer, and because each conducting layer is an independent electrochemical machining electrode, the conducting layers can be respectively regulated and controlled according to the machining requirements without influencing the machining effect of other areas, so that the micro grooves with different widths and different depths can be machined on the same workpiece at one time, and the machining efficiency is improved.
EXAMPLE seven
As shown in fig. 17 to 20, fig. 17 is a current density distribution diagram prepared by using a laminated tool electrode for electrochemical machining of micro-grooves, in which the height of the conductive layer is consistent when the electronic load voltage Δ U = 0.0V; FIG. 18 is a graph of current density distribution for a stacked tool electrode of the described electrolytically machined micro-grooves with uniform conductive layer height at an electrical load voltage Δ U = 5.0V; FIG. 19 is a graph of current density distribution for a stacked tool electrode of the described electrolytically machined micro-grooves with uniform conductive layer height at an electrical load voltage Δ U = 10.0V; FIG. 20 is a graph of current density distribution produced by a stacked tool electrode for electrochemical machining of micro-grooves with uniform conductive layer height at an electrical load voltage Δ U = 15.0V.
FIGS. 17 to 20 are graphs showing the current density distribution on the surface of the conductive layer when the electrode is fabricated, wherein the current density distribution on the conductive layer is observed to be slightly higher in the region near the insulating layer and smaller in the central region due to the current fringe effect; as the electronic load voltage delta U is gradually increased, the current density on the surface of the conductive layer tends to be reduced; in addition, under the same electronic load voltage, the current density of the two conducting layer surfaces near the edge of the tool electrode is obviously higher than that of other areas.
FIG. 21 is a graph showing the current density distribution of the stacked tool electrode with the electrolytically machined micro-grooves as the electrical load voltage is gradually decreased, as shown in FIGS. 21 and 22; FIG. 22 is a graph of current density distribution for a stacked tool electrode for electrochemical machining of micro-grooves with a first increase and a subsequent decrease in electrical load voltage;
fig. 21 and 22 are current density distribution diagrams of the conductive layer surface of the electronic load under the condition of regular distribution. Fig. 21 and 22 show that under the mutual influence of unequal electric fields, the current density on the conductive layer at the position of the smallest electronic load is increased, and the current density value on the conductive layer at the position of the largest electronic load is decreased; it is also shown that the electronic load Δ U =0V suppresses the electric field intensity of the nearby conductive layer, with a consequent reduction in current density.
FIG. 23 is a graph showing a current density distribution obtained by using a laminated tool electrode in which the height of the conductive layer is irregular in the electrolytically machined micro-grooves, as shown in FIG. 23; in fig. 23, the current density on the conductive layer at the minimum value of the electronic load is influenced by the mutual influence of the electric fields, resulting in a current density value larger than that when the electronic loads are equal.
Under the condition of unequal electronic loads, the position of the conductive layer with the smallest electronic load has great influence on the distribution of current density on the conductive layer. If the electronic load is the minimum value, i.e. Δ U =0V, the current density on the surface of the conductive layer increases, the electric field intensity in the vicinity affected by the increase decreases, the current density value on the conductive layer decreases, and the influence increases as the potential increases, and the current density value with a large electronic load is much smaller than the current density value with the same electronic load under the influence of the electric field in the maximum region, as shown in fig. 17 to 20.
As shown in fig. 24, fig. 24 is a current density distribution diagram of the surface of the workpiece when machined with the prepared laminated tool electrode.
The prepared laminated tool electrode is used for processing, and due to the dividing influence of the insulating layer, an electric field and a flow field which are respectively independent are formed, so that the mutual influence of the ground electric fields is avoided, and during processing, the current density value on the surface of a workpiece is as shown in figure 24, the smaller the voltage value of the electronic load is, the larger the current density value on the surface of the workpiece is, and the current density values are equal, so that the group micro-grooves with high precision and good processing stability can be processed on the surface of the workpiece by the electrode structure and the electrolytic processing method.
The foregoing is merely a preferred embodiment of the invention, which is intended to be illustrative and not limiting. It will be understood by those skilled in the art that various changes, modifications and equivalents may be made therein without departing from the spirit and scope of the invention as defined in the appended claims.
Claims (5)
1. The electrochemical machining method of the laminated tool electrode for the electrochemical machining of the micro groove is characterized in that the laminated tool electrode for the electrochemical machining of the micro groove comprises a plurality of conducting layers and insulating layers arranged on two sides of the conducting layers, the conducting layers and the insulating layers are alternately arranged at intervals, the heights of the conducting layers are smaller than those of the insulating layers, and the machined end faces of the conducting layers are parallel;
the method comprises the following steps:
s1, manufacturing the laminated tool electrode of the electrochemical machining micro-groove consisting of the conducting layer and the insulating layer;
s2, placing the workpiece below the laminated tool electrode of the electrochemical machining micro-groove and closely attaching to the insulating layer of the laminated tool electrode of the electrochemical machining micro-groove;
s3, the workpiece and the conducting layer are respectively and electrically connected with the positive electrode and the negative electrode of a power supply;
s4, spraying an electrolyte solution to the machining region so that the electrolyte solution passes through the machining region formed between the conductive layer, the insulating layer and the workpiece;
and S5, switching on a power supply, and adjusting the electronic load to carry out electrolytic machining.
2. The method of electrochemical machining of a laminated tool electrode for electrochemical machining of a micro-groove of claim 1, wherein the insulating layer has a thickness greater than 250 μm.
3. The method of electrochemical machining of a laminated tool electrode for electrochemical machining of a micro-groove of claim 1, wherein the conductive layer has a thickness of between 20 microns and 8 mm.
4. The method of claim 1, wherein the micro-groove electrochemical machining laminated tool electrode is formed by disposing a laminated tool electrode composed of a plurality of conductive layers and a plurality of insulating layers above a flat metal electrode, wherein a machining gap is provided between the flat metal electrode and the laminated tool electrode, wherein the conductive layer is an electrolytic anode, the flat metal electrode is an electrolytic cathode, and wherein the machining gap is sprayed with an electrolyte to turn on a power supply to prepare the laminated tool electrode.
5. The method of electrochemical machining of a laminated tool electrode for electrochemical machining of a micro-groove according to claim 4, wherein the machined end face of the conductive layer is adjusted by an electronic load when the laminated tool electrode for electrochemical machining of a micro-groove is prepared.
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