CN1236337A - 放电加工用多孔性电极线及其制造方法 - Google Patents
放电加工用多孔性电极线及其制造方法 Download PDFInfo
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Abstract
本发明涉及放电加工用多孔性电极线及其制造方法。它是使含铜的第一金属线材通过比第一金属气化温度低的第二金属的电镀池,由于第一金属和第二金属的扩散反应,在上述线材的表面上形成比第一金属和第二金属硬度高、延伸率低的合金层,再在合金层上形成由第二金属构成的外镀层后进行线材的拉拔加工,使上述合金层及外镀层中形成裂纹。该电极线与传统的镀锌线相比使加工速度至少提高15%,而此加工速度的改善,是由于线材表面的多孔性构造增加了表面积进而增加了用加工液冷却电极线的速度而达到的。
Description
背景技术
发明的领域
本发明涉及放电加工用电极线及其制造方法,特别是涉及改进了加工速度的多孔性电极线及其制造方法。
背景技术的说明
图1是表示电极线放电加工机的略图。电极线穿过工件(1)的起始孔(7)而***,并且供应此线通过该孔。在电线(2)和孔(7)内部间施加高频电压以在它们之间开始形成电弧放电。然后,在电弧放电中通过熔解工件使待加工的工件达到所希望的形状,并用加工液和电极线与工件间的瞬时气化力除去加工碎屑。按照机械加工原理,该电极线放电加工机包括电源供给装置、电极线输送装置、工件输送装置和加工液的循环装置。
一般,如图1中箭头所示,工件输送装置在工件加工过程中在一个垂直于电极线2喂进方向的平面中移动。电极线2从供给辊3连续地送出,通过工件两侧的导线辊5、5’卷绕到卷线辊4上。
之后,在工件1和电极线2之间施加高频电压,对工件进行加工。此时为了除去加工时产生的热,向加工区域供给作为加工液的脱离子纯水。放电加工的效率,特别是加工速度,与加工液的供给速度、加工电流密度、放电波形及频率等有着密切关系,通过调节这些参数可以改善加工效率。
过去,使用纯铜线作为电极线,这是因为纯铜的延伸率大、易于加工成细线且导电性也好的缘故。可是,由于纯铜线的拉伸强度低,在放电时,因为不能加以过大的张力,所以不能抑制电极线的振动,结果加工精度不好,易于断线,而且加工速度缓慢。为此,高精度的特殊加工要使用钼线、钨线等精密加工用的高强度线,而一般加工要使用以65/35重量百分比黄铜线为代表的黄铜电极线。
黄铜电极线与纯铜比较约有2倍以上的拉伸强度,而且由于作为合金成分的锌存在而提高了放电稳定性、气化***力等,因此可以加快加工速度。
然而,近年来,随着放电加工利用的扩大,强烈地要求进一步提高强度及加工速度,开发出了在黄铜中添加Al、Si等微量元素,使强度和加工速度得到提高的电极线等。
另一方面,已知黄铜合金中的锌含量越高,可得到的加工速度就越高,但是锌含量超过40%时,则会形成脆性的β相,所以拉伸成细线就比较困难了。
在USP4,278,404中公开了在黄铜的表面上覆盖锌或者锌合金的电极线及其制造方法。也就是,公开了在铜、黄铜或钢等拉伸强度和电导率比较高的芯线上电镀气化温度较低的锌、镉、锡、锑、铋及其合金的镀层电极线及其制造方法。按此,电极线要求的拉伸强度和通电在芯线上完成,而通过电镀气化温度低的材料,可以提高冷却速度及洗净力,这样就进一步增加了加工速度。另外,镀层在加工时由于热作用而易于气化,所以还起到芯线免受热冲击的保护作用。这样的锌线制造方法,可以为在最终伸长加工后的细线上电镀锌,或线材最后加工前在适当直径的线材上电镀锌后再进行拉伸成最终细线的操作。
另外,另一种加工速度的改善方法,在USP4,977,303中也已公开。按照此方法,包括了三个工序,即金属芯线热处理后,将可通过与芯线扩散反应形成混合合金层的锌、镉或其合金电镀在芯线上的工序,和将镀层的芯线在至少700℃的氧化气氛中热处理,使芯线金属和镀层金属间发生扩散,形成混合合金层例如铜锌合金层的工序,以及将上述热处理后的镀层线伴随加工硬化的同时拉伸成细线的工序。此时,电极线的构造是由芯线和覆盖芯线的混合合金镀层和最外层的氧化层构成的。此时,氧化层可以起到防止出现放电加工时电极线和工件间的短路的可能,而与加工速度实质上无关。具有上述构造的镀层的电极线的加工速度的提高原因在于形成上述的铜-锌合金层的热处理,但其机理未予以揭示。
另外,USP4,686,153中公开了镀以锌合金的铜包钢芯线。由于钢芯线内的强度高,可提供优良的加工精度,而包覆的铜可以给这种线提供良好的导电性。这种铜包钢线上用电镀或者热浸镀锌后,通过热处理工序,形成铜一锌合金层。特别是当合金层中锌含量为40-50重量百分比时,要比只是简单镀锌的铜包钢线可以得到更高的加工速度。这样镀锌的铜包钢线包括一铜包钢芯和一铜一锌合金层,此时,合金层中锌的含量是10-50重量百分比,但优选含量为40-50重量百分比。此种线的制造方法包括了提供铜包钢线芯线的工序和将锌电镀在上述芯线上的工序以及将上述镀锌的芯线拉伸成所需直径的细线的工序和热处理工序。此工序使镀锌层转换成铜-锌合金层,锌含量在10-50重量百分比的范围,优选含量为40-50重量百分比。这样,沿径向向内,锌浓度逐渐降低。另外,上述拉伸工序中可以在热处理工序前,而镀锌可以采用热浸镀的方法。
如上所述,在公知的技术中,通过将锌那样的熔点和气化温度比芯线金属低的材料电镀在芯线上来提高加工速度,进而通过热处理使含铜的芯线与镀层金属之间扩散而在芯线外形成铜-锌合金层,进一步改善加工速度。但是这些公开的专利技术是通过电镀材料、即选择比芯线气化温度低的金属来提高加工速度,所以由于材料的固有性质使加工速度的提高受到了限制。
发明的公开
本发明的目的在于提供一种放电加工用的镀层电极线,该电极线的表面积增加,从而增加了与加工液的接触面积,提高了线的冷却速度,进而提高了加工速度。
本发明的另一个目的在于提供一种放电加工用的镀层电极线,使加工液不仅接触电极线外部,也接触其内部,从而提高冷却速度,进而提高加工速度。
本发明还有一个目的在于提供多孔性电极线的制造方法,该方法不需要附加的工序就增大了线的表面积。
本发明再有一个目的在于提供一种在不妨碍加工精度的同时提高加工时洗净力的电极线。
为完成本发明的这些目的,本发明的方法包括三个工序,即提供由含铜的第一金属制成的第一直径线材的工序,和将上述线材在一定时间内通过比第一金属气化温度低的熔化了的第二金属的镀槽而热浸镀所述线材,并通过上述第一金属和第二金属间的扩散反应在上述线材的表面形成比第一金属和第二金属硬度高而延伸率低的一合金层以及由第二金属构成的一外层的工序,以及,将形成了合金层和外层镀层的线材拉伸至一第二直径,从而由于上述合金层的高硬度和低延伸率而在上述合金层及外层镀层中形成裂纹的工序。
此时,第一金属可使用纯铜或由36-67%重量的铜和33-37%重量的锌构成的黄铜。另外,第二金属可使用锌、铝或锡。
特别是在本发明中,为了在第一金属构成的第一直径的线材上镀上一定厚度的第二金属,需要将第一直径的线材浸渍在镀槽中一定的时间。此时,上述一定时间是依镀槽的长度和第一直径线材的卷绕速度而决定的。因此,卷绕速度快时,希望镀槽的长度长些好,而镀槽短时则需要慢慢地卷绕。卷绕速度和镀槽长度的选择使在第一直径的线材上形成3-10μm厚度的镀层金属就可以。
在本发明电极线的制造方法中,为了稳定电极线的机械性能,还可以将制造的电极线进行热处理。根据需要也可以包括除去合金层外的第二金属层即外层镀层的工序。本发明的方法制造出的放电加工用多孔性电极线包括一芯线和在上述芯线上形成的合金层;上述芯线由合铜的第一金属构成;而上述芯线上形成的合金层是在热浸镀过程中上述第一金属和比上述第一金属气化温度低的第二金属进行扩散反应而形成,上述合金层的硬度最高;上述合金层含有与电极线的长度方向相垂直的裂纹。
这些构造使得第一直径线材在一定时间内通过具有比第一金属气化温度低的第二金属的熔融镀槽进行热浸镀时,在线材的表面上,由于第一金属和第二金属的扩散反应形成了比第一金属及第二金属硬度高、延伸率低的合金层,合金层上面又形成由第二金属构成的外层镀层,再拉伸此包覆合金层和外镀层的线材至第二直径,所以最终产品中由合金层和外层镀层包围的第一金属成为芯线。
在这样的构造中,含有上述合金层及外镀层中的裂纹的多孔特性是在上述拉伸工序时形成的。
本发明的作为放电加工用的电极线,可除去外镀层,使放电加工用电极线只含有芯线和上述芯线上形成的合金层;上述芯线由含铜的第一金属构成;上述芯线上形成的合金层是在热浸镀过程中,由于上述第一金属与比上述第一金属气化温度低的第二金属间进行扩散反应而形成,上述合金层的硬度最高;上述合金层在与电极线长度方向垂直的方向上含有构成多孔性的结构的裂纹。
实施本发明的最佳方式下面用实施例详细地说明本发明。
图2是表示本发明放电加工用多孔性电极线的制造工艺的图。参照该图,提供了0.9mm直径的由锌35%重量、铜65%重量构成的黄铜中间线材12。将此中间线材12在一定时间内通过比黄铜气化温度低的熔融锌镀槽,在中间线材12的外面热镀锌,此时在中间线材12的表面上由于熔融在镀槽10中的锌和黄铜的扩散反应,形成了比黄铜和锌的硬度高、延伸率低的合金层,其上面形成了外锌层,合金层具有最高的硬度。
图3A是由黄铜构成的中间线材上镀了锌层的断面照片,图3B是图3A的一部分的放大照片,参照图3B,可以看出在中间线材12上是分步形成合金层和镀锌层。
形成了合金层及镀锌层的中间线材12通过拉伸装置14拉伸至适当的直径,例如0.05至0.35mm。此时中间线材12和镀锌层之间的合金的硬度最大,且由于与其他层的硬度及延伸率不同,拉伸此合金层时,在镀层上大约垂直于拉伸方向产生裂纹,成为海绵状的多孔性结构。
这样的细线经过热处理工序,其机械性能可以进一步稳定。
图4A是表示上述拉伸了的线的多孔性表面的照片,图4B是本发明的多孔性电极线的断面照片。
参照图4A,在电极线的表面上,相对于电极线的长度方向大约成直角方向发生了裂纹。这样的裂纹是合金层被拉伸后发生的,如图4B所示,由于裂纹的作用合金层及锌镀层形成了海绵状的多孔层。
这样结构的多孔性电极线包括黄铜构成的芯线21和围绕它的镀锌层23。通过使用芯线21可以满足作为电极线要求的电气电导率以及机械强度,镀锌层23由于使用了比芯线21上所用的材料的熔点及气化温度低的锌材料,所以放电加工时,保护芯线,并可提高加工速度。另外,由于上述镀层23上具有多孔性构造,所以可得到比以往电极线更优良的冷却速度。这是由于多孔性构造使电极线的表面积显著增加后,与放电加工时的加工液的接触面积增加的缘故。对于一种给定材料,这种冷却能力的提高,可以使得在同一条件下将放电加工时的电极线的温度维持在比以往电极线更低的温度,所以可以达到①提高相对的导电率,加工速度提高;②高温下也可以相对的提高芯线21的机械拉伸强度。因此,按照本发明,冷却能力提高了的多孔性电极线与以往的镀层电极线相比至少可以提高15%的加工速度,且加工精度也提高。对于镀层上所使用的材料,需要其性质为其熔点及气化温度比芯线的低,在铜或黄铜的芯线金属上能进行热浸镀,且在进行热浸镀时通过与铜的扩散反应可以形成硬度比较高的合金层且这种金属包括锌、铝、锡等。因此,在这样的电极线拉伸时,由于芯线和外镀锌层间的合金层延伸率差,在镀层上可以形成多孔性构造。
如图3A所示,在此电极线的表面上可观察到均匀分布的裂纹。这样的裂纹大体上与电极线的长度方向相垂直而形成,另外,裂纹也有的是在晶粒间形成,大体上是晶粒边界。另一方面,电极线的表面不是尖锐地突出,而具有大致均匀的电极线外圆周。因此,放电加工时电极产生碎屑的可能性很小,通过这样的具有裂纹的多孔性结构,将加工时在工件上产生的碎屑等通过裂纹而被除去,所以洗净力比以往的电镀线提高。实施例
准备成分为63-67%重量铜和33-37%重量锌的直径为0.9mm的黄铜线作为中间材。在此中间线材上进行热浸镀。热浸镀的材料可使用锌、铝、锡及其合金,特别优选的是锌。在通常的热浸镀工艺中,中间线材通过酸洗及碱脱脂进行预处理后,通过氯化铵溶剂池。用溶剂处理过的中间线材通过熔融锌槽后,熔融锌被电镀上,此时,锌槽的温度维持在400-500℃,在1-10秒钟内中间线材进行镀锌,形成规定的锌层及铜-锌的合金层。此时,中间线材和锌在接触的分界面上由于扩散反应而产生铜-锌合金层,其上面是锌层。此时,形成的铜-锌合金层是线材中硬度最高的部分,延伸率比芯线低。
此时,在黄铜线材的表面形成3-8μm的铜-锌合金层,最***形成1-2μm的锌层。这些锌及铜-锌合金层是粗密的镀层。此合金层为外面的锌层与中间线材提供了好的粘着性,另一方面合金层具有比较高的硬度。
上述的热浸镀锌后的中间材,在空气中冷却后,通过拉伸,成为0.05-0.03mm等所要求直径的细线。在拉伸阶段中,可以除去一部分最外面的锌层。拉伸成细线时,由于镀层的延伸率比芯线低、硬度比芯线高,所以在拉伸加工成细线过程中,在镀层中均匀地发生裂纹,形成多孔性结构。这样的裂纹主要是在晶粒边界上,并被电磁化。另外因拉伸线是在线长的方向,所以这些裂纹的方向大约与线长方向垂直地形成。而后,加工好的细线在300-600℃温度的气氛中加热处理约1-2秒钟可以稳定芯线的机械性能,从而生产出多孔性电极线。产业上的可利用性
本发明的多孔电极线与常规的镀锌线相比,至少可以提高15%的加工速度。这种加工速度的提高是由于线表面的多孔性结构使表面积增加,加速了用加工液冷却的速度的缘故。另一方面,上述多孔性线有着均匀的圆周表面,表面上不含有突出部,所以不会产生对加工精度不利的影响,相反,由于多孔性可以容易地除去加工时发生的碎屑,所以洗净力优良,可以期待加工精度的提高。因此,按照本发明多孔性电镀电极线的制造方法,与过去方法相比,不需增加工序,其加工速度和洗净力比过去的镀锌线相比可以明显提高。
附图简介
图1为表示一般放电加工机的构成及其原理的简图。
图2为表示放电加工用多孔性电极线的制造工艺图。
图3A是在黄铜构成的中间线材上镀锌后的断面照片;
图3B是图3A照片的一部分放大后的照片。
图4A是本发明的多孔性电极线的表面照片;
图4B是本发明的多孔性电极线的断面的照片。符号的说明
12 中间线材
14 拉伸装置
21 芯线
23 镀锌层
Claims (23)
1.放电加工用电极线的制造方法,其特征是包括下列步骤:提供由含铜的第一金属构成的第一直径线材;将上述线材在一定时间内通过比第一金属气化温度低的、熔化了的第二金属的熔池进行热浸镀,由于上述第一金属和第二金属的扩散反应,在上述线材的表面形成比第一金属及第二金属硬度高、延伸率低的合金层,并在合金层上面形成由第二金属构成的外镀层;以及将形成了合金层和外镀层的上述线材拉伸至第二直径,由于上述合金层的高硬度和低延伸率而在上述合金层及外镀层中形成裂纹。
2.权利要求1所述的电极线的制造方法,其特征是还包括使上述细线的机械性能稳定的热处理工序。
3.权利要求1或2所述的电极线的制造方法,其特征是上述的第一金属是黄铜。
4.权利要求3所述的方法,其特征是上述的第二金属是锌、铝、或锡。
5.权利要求4所述的电极线的制造方法,其特征是上述的一定时间是指在上述线材上充分形成3-10μm厚度镀层的时间。
6.权利要求1所述的电极线的制造方法,其特征是上述第二金属是锌、铝、或锡。
7.权利要求6所述的电极线的制造方法,其特征是上述的一定时间是指在上述线材上充分形成3-10μm厚度镀层的时间。
8.权利要求1所述的电极线的制造方法,其特征是上述的一定时间是指在上述线材上充分形成3-10μm厚度镀层的时间。
9.权利要求1所述的电极线的制造方法,其特征是还包括除去在合金层上形成的第二金属层的工序。
10.权利要求9所述的电极线的制造方法,其特征是上述第一金属是黄铜。
11.权利要求9或10所述的电极线的制造方法,其特征是上述第二金属是锌、铝、或锡。
12.权利要求11所述的电极线的制造方法,其特征是上述的一定时间是指在上述线材上充分形成3-10μm厚度镀层的时间。
13.权利要求9或10所述的电极线的制造方法,其特征是上述的一定时间是指在上述线材上充分形成3-10μm厚度镀层的时间。
14.放电加工用多孔性电极线,其特征是它包括芯线和在上述芯线上形成的合金层,以及在上述合金层外形成的、由比上述芯线气化温度低的第二金属构成的外镀层;
上述的镀层由含铜的第一金属构成;
在上述芯线上热浸镀镀层的过程中,由上述第一金属和第二金属的扩散反应形成的合金层的硬度最高;
上述的合金层及外镀层中有与电极线长度方向大约垂直的裂纹。
15.权利要求14所述的多孔性电极线,其特征是上述合金层及外镀层中的裂纹是在上述芯线沿电极线长度方向拉伸时形成的。
16.权利要求14或15所述的电极线,其特征是上述的第一金属是黄铜。
17.权利要求16所述的电极线,其特征是上述的第二金属是锌、铝、或锡。
18.权利要求15所述的电极线,其特征是上述第二金属是锌、铝、或锡。
19.放电加工用多孔性电极线,其特征是该电极线包括芯线和在上述芯线上形成的合金层;
上述芯线由含铜的第一金属构成;
在上述芯线上形成的合金层,在热浸镀过程中由上述第一金属和第二金属的扩散反应形成且硬度最高;
上述的合金层中有与电极线长度方向大约垂直的裂纹。
20.权利要求19所述的电极线,其特征是上述合金层中的裂纹是在上述芯线沿电极线长度方向拉伸时形成的。
21.权利要求19或20所述的电极线,其特征是上述第一金属是黄铜。
22.权利要求21所述的电极线,其特征是上述的第二金属是锌、铝、或锡。
23.权利要求20所述的电极线,其特征是上述的第二金属是锌、铝、或锡。
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EP (1) | EP0930131B1 (zh) |
JP (4) | JP3718529B2 (zh) |
KR (4) | KR100518729B1 (zh) |
CN (1) | CN1078831C (zh) |
AT (1) | ATE320882T1 (zh) |
BR (1) | BR9806117A (zh) |
CA (1) | CA2267621C (zh) |
DE (1) | DE69833944T2 (zh) |
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CN1305624C (zh) * | 2001-12-21 | 2007-03-21 | 瑟莫康柏克特公司 | 用于放电加工的电极线、该电极线的制造方法及用途 |
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CN102369077A (zh) * | 2010-02-02 | 2012-03-07 | 冲电线株式会社 | 线放电加工用电极线及其制造方法、放电加工方法 |
CN102756188A (zh) * | 2011-04-29 | 2012-10-31 | 成机哲 | 用于电火花加工的焊丝及其制造方法 |
CN102756188B (zh) * | 2011-04-29 | 2016-03-30 | 成机哲 | 用于电火花加工的焊丝及其制造方法 |
CN102784982A (zh) * | 2011-05-20 | 2012-11-21 | 昆山市瑞捷精密模具有限公司 | 快走丝电火花加工用钼铜合金电极线及其制备方法 |
CN103769703A (zh) * | 2012-10-23 | 2014-05-07 | 成机哲 | 用于电火花加工的焊丝及其制造方法 |
CN103769703B (zh) * | 2012-10-23 | 2017-06-23 | 成机哲 | 用于电火花加工的焊丝及其制造方法 |
CN104994984A (zh) * | 2013-09-09 | 2015-10-21 | 住友电气工业株式会社 | 线放电加工用电极线及其制造方法 |
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CN105033377A (zh) * | 2015-07-30 | 2015-11-11 | 宁波博威麦特莱科技有限公司 | 一种高效低损耗电火花腐蚀加工用电极丝及其制备方法 |
CN105033377B (zh) * | 2015-07-30 | 2017-05-10 | 宁波博威麦特莱科技有限公司 | 一种高效低损耗电火花腐蚀加工用电极丝及其制备方法 |
CN105269100A (zh) * | 2015-10-30 | 2016-01-27 | 长治清华机械厂 | 一种补偿电极丝以降低电火花线切割中电极丝损耗的方法 |
CN108856935A (zh) * | 2018-07-18 | 2018-11-23 | 宁波正锦和精密贸易有限公司 | 放电加工用电极丝及其制造方法 |
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KR100518733B1 (ko) | 2005-10-05 |
WO1999006183A1 (fr) | 1999-02-11 |
US6306523B1 (en) | 2001-10-23 |
JP3718617B2 (ja) | 2005-11-24 |
JP2002018649A (ja) | 2002-01-22 |
CA2267621A1 (en) | 1999-02-11 |
DE69833944T2 (de) | 2006-11-16 |
ATE320882T1 (de) | 2006-04-15 |
ES2259815T3 (es) | 2006-10-16 |
US6482535B2 (en) | 2002-11-19 |
BR9806117A (pt) | 2000-01-25 |
KR19990014314A (ko) | 1999-02-25 |
CN1078831C (zh) | 2002-02-06 |
EP0930131A1 (en) | 1999-07-21 |
US6492036B2 (en) | 2002-12-10 |
EP0930131A4 (en) | 2002-10-30 |
JP2004314303A (ja) | 2004-11-11 |
JP3718529B2 (ja) | 2005-11-24 |
US20020092831A1 (en) | 2002-07-18 |
KR100518727B1 (ko) | 2005-10-05 |
JP4012895B2 (ja) | 2007-11-21 |
JP4012876B2 (ja) | 2007-11-21 |
JP2005096060A (ja) | 2005-04-14 |
KR100518729B1 (ko) | 2005-11-25 |
KR100518731B1 (ko) | 2005-10-05 |
DE69833944D1 (de) | 2006-05-11 |
US20010014411A1 (en) | 2001-08-16 |
PT930131E (pt) | 2006-07-31 |
EP0930131B1 (en) | 2006-03-22 |
CA2267621C (en) | 2007-10-16 |
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Granted publication date: 20020206 |
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