WO2012067078A1 - ワイヤ電極アニール処理方法及びワイヤ放電加工機 - Google Patents
ワイヤ電極アニール処理方法及びワイヤ放電加工機 Download PDFInfo
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- WO2012067078A1 WO2012067078A1 PCT/JP2011/076215 JP2011076215W WO2012067078A1 WO 2012067078 A1 WO2012067078 A1 WO 2012067078A1 JP 2011076215 W JP2011076215 W JP 2011076215W WO 2012067078 A1 WO2012067078 A1 WO 2012067078A1
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- 0 CC1=CCC*1 Chemical compound CC1=CCC*1 0.000 description 1
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- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
- C21D1/00—General methods or devices for heat treatment, e.g. annealing, hardening, quenching or tempering
- C21D1/34—Methods of heating
- C21D1/40—Direct resistance heating
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- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
- H05B3/00—Ohmic-resistance heating
- H05B3/0004—Devices wherein the heating current flows through the material to be heated
-
- 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
- B23H7/00—Processes or apparatus applicable to both electrical discharge machining and electrochemical machining
- B23H7/02—Wire-cutting
- B23H7/08—Wire electrodes
- B23H7/10—Supporting, winding or electrical connection of wire-electrode
-
- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
- C21D11/00—Process control or regulation for heat treatments
-
- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
- C21D9/00—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor
- C21D9/52—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor for wires; for strips ; for rods of unlimited length
- C21D9/525—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor for wires; for strips ; for rods of unlimited length for wire, for rods
-
- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
- C21D9/00—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor
- C21D9/52—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor for wires; for strips ; for rods of unlimited length
- C21D9/54—Furnaces for treating strips or wire
- C21D9/56—Continuous furnaces for strip or wire
-
- 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
- B23H7/00—Processes or apparatus applicable to both electrical discharge machining and electrochemical machining
- B23H7/02—Wire-cutting
- B23H7/08—Wire electrodes
Definitions
- the present invention relates to a wire electric discharge machine for machining a workpiece by generating an electric discharge phenomenon between the workpiece and a wire electrode, and in particular, a pair of electrodes are arranged at two predetermined points of the wire electrode, and the wire electrode
- the present invention relates to an annealing method for a wire electric discharge machine that corrects a bending wrinkle between two points by passing a current through the electrode while applying tension to the wire to heat the wire electrode.
- Patent Document 1 proposes to heat a wire electrode and perform an annealing treatment in order to reduce bending wrinkles generated in the wire electrode for the purpose of improving the processing capability of the wire electric discharge machine.
- Patent Document 2 discloses that the thermal elongation of the wire electrode is measured and used for the purpose of controlling the temperature of the wire electrode to a predetermined temperature during the annealing process.
- Patent Document 3 describes a method for estimating the temperature of a wire electrode during processing from a current value and a resistance value. Further, as shown in FIGS. 51 and 53 of Non-Patent Document 1, it is known that the mechanical properties of brass, which is a material often used as a wire electrode of an electric discharge machine, vary with temperature.
- JP 54-141490 A page 462, lower left 15-20 lines
- JP2003-94253A paragraph [0008] on page 3
- JP 6-31536 A paragraphs [0015] to [0025] on page 3)
- Patent Document 1 describes means for measuring the wire temperature and controlling the current flowing to the wire electrode according to the measurement result in order to set the heating temperature of the wire electrode to the recrystallization temperature or less.
- no specific means or method for measuring the temperature of the wire electrode is described.
- the wire diameter used for electric discharge machining is 0.02 to Since the wire temperature changes due to heat transfer to the contacted object in the contact type, it is difficult to accurately measure the temperature. Even in the non-contact type, the temperature is actually measured because the wire is thin and sufficient sensitivity cannot be obtained, or the device becomes complicated and difficult to mount on an electric discharge machine easily. Difficult to do.
- a temperature measuring method using a resistance temperature detector that detects the temperature by a resistance value change with respect to the temperature of a platinum wire or the like is applied, and during annealing of the wire electrode, between the annealing electrodes connected to the wire electrode. It is assumed that the wire temperature is estimated from the temperature coefficient of the resistance value of a known wire electrode material by measuring the voltage directly or via a bridge circuit. Although the method disclosed in Patent Document 3 does not mention the use of the temperature coefficient, it is described that the resistance value is obtained from the current value and the voltage value, and the temperature is estimated from this value. It is thought that this principle is used.
- the resistance value of the wiring portion to the resistance temperature detector becomes a measurement error, and therefore a three-wire or four-wire wiring method is used so that the resistance value of the wiring portion does not become a problem.
- the wire electrode is disposable, and a new wire electrode is always drawn out, and an annealing electrode is connected thereto.
- the annealing electrode is movable so that it does not become an obstacle when the wire travels other than annealing, so the wire electrode when the wire is moved or the annealing electrode is connected Depending on the contact condition, the contact resistance between the annealing electrode and the wire electrode varies.
- the wire electrode is stretched during the annealing process.
- the fluctuation of the contact resistance and the wire electrode stretching are not considered in the conventional temperature measuring method using a resistance temperature detector or the method disclosed in Patent Document 3, and thus have a great influence on the estimated temperature. It was difficult to apply to an electric discharge machine.
- Patent Document 3 there is a reference to a method of measuring a voltage using a non-contact electrode.
- the resistance value of the wire electrode is minute unless it has an extremely thin diameter, it is difficult to accurately measure the resistance value of the wire. It is.
- An object of the present invention is to provide a wire electrode annealing method and a wire electric discharge machine capable of improving the straightening treatment of the wire by annealing by keeping the temperature of the wire electrode at a predetermined temperature during the annealing of the wire electrode. To do.
- a wire electrode annealing method is a wire electric discharge machine that processes a workpiece by generating an electric discharge phenomenon between the workpiece and the wire electrode.
- a pair of annealing electrodes are arranged at two predetermined points of the wire electrode, and a current is passed through the annealing electrode in a state where tension is applied to the wire electrode to heat the wire electrode, thereby bending between the two points.
- the annealing method of wire electric discharge machine that corrects the load, measure the current value and voltage value from the heating power supply that heats by energizing the wire electrode, and divide the voltage value by the measured current value.
- Calculate the resistance value calculate the increment of the resistance value of the wire electrode from the amount of increase in the load resistance value based on the load resistance value immediately after the start of heating, and the resistance value of the wire electrode itself at room temperature, Estimating a temperature rise value of the wire electrode based on the temperature coefficient of the specific resistance of and specific resistance, and controlling the turn-on states of the wire electrode based on the estimated temperature rise value.
- the wire electric discharge machine processes a workpiece by generating an electric discharge phenomenon between the workpiece and the wire electrode, and arranges a pair of annealing electrodes at two predetermined points of the wire electrode. Then, in a wire electric discharge machine that corrects the bending wrinkle between two points of the wire electrode by supplying a current through the annealing electrode with tension applied to the wire electrode and heating the wire electrode, power is applied to the wire electrode.
- a heating power supply that heats by supplying power
- a current-voltage measuring unit that measures the current value and voltage value from the heating power supply that energizes the wire electrode, and a load by dividing the voltage value by the measured current value
- Calculate the resistance value calculate the increase in the resistance value of the wire electrode from the amount of increase in the load resistance value based on the load resistance value immediately after the start of heating, and the resistance value at normal temperature of the wire electrode itself, and set the preset wire Electric
- an estimation unit that estimates a temperature increase value of the wire electrode based on the specific resistance and a temperature coefficient of the specific resistance, and a control unit that controls the energization state of the wire electrode based on the estimated temperature increase value.
- the processing result is greatly influenced by the temperature at the time of the processing, but the wire temperature during the annealing process is set by a simple method based on the sensing of the current value and voltage value of the power source for heating. Because it is possible to detect the heat, it is possible to control the heating appropriately according to the temperature condition of the wire, and the ability to bend and bend the wire by annealing treatment and the straightness of the wire are improved. There is an effect of improving.
- FIG. 1 is a diagram showing a configuration of a first embodiment of a wire electric discharge machine according to the present invention.
- FIG. 2 is a sequence diagram showing an example of the procedure of the annealing process of the present embodiment.
- FIG. 3 is a diagram showing an example of an annealing process sequence in the case of performing correction by wire elongation.
- FIG. 1 is a diagram showing a configuration of a first embodiment of a wire electric discharge machine according to the present invention.
- the wire electric discharge machine 100 has a tension setting roller 1, a first annealing electrode 2, a first cutting electrode 3, a second annealing electrode (second annealing) along the path of the wire electrode 6. (Also serving as a cutting electrode) 4, a pinch roller 5, an upper guide block 7, a lower guide block 8, a lower roller 9, and a collection unit roller 10 are provided in this order.
- the wire electric discharge machine 100 includes a control device 80 that controls the operation of each of the above devices, and a heating power supply device 85 that supplies power to the wire electrode 6 when performing the annealing process.
- the heating power supply device 85 is provided with a current voltage measuring unit 75 that measures and outputs a current value and a voltage value to be passed through the wire electrode 6.
- the control device 80 includes an estimation unit 65 that estimates the temperature rise value of the wire electrode 6, a control unit 70 that controls the energization state of the wire electrode 6 based on the estimated temperature rise value, and a storage unit that stores various settings. 60.
- the estimation unit 65 calculates the load resistance value by dividing the voltage value by the current value based on the current value and the voltage value measured by the current / voltage measurement unit 75, and uses the load resistance value immediately after the start of the annealing process as a reference.
- the increase in the resistance value of the wire electrode 6 is calculated from the increase amount of the load resistance value and the resistance value of the wire electrode 6 itself at room temperature, and based on the specific resistance of the wire electrode 6 and the temperature coefficient of the specific resistance set in advance. Thus, the temperature rise value of the wire electrode 6 is estimated.
- FIG. 1 there are predetermined electrical connections between the devices around the wire electrode 6 shown on the left side of the drawing, the control device 80, and the heating power supply device 85, but they are omitted because they are complicated.
- the wire electric discharge machine 100 is a processing machine that intermittently generates electric discharge between the traveling wire electrode 6 and the object to be processed, and processes the object to be processed by energy at the time of discharge.
- the wire electrode 6 is supplied in a state of being wound around a wire hobbin (not shown), reaches the lower roller 9 from the tension setting roller 1 through the upper guide block 7 and the lower guide block 8, changes the direction in the lower roller 9, and then recovers. It is discharged through the roller 10.
- the object to be processed is disposed between the upper guide block 7 and the lower guide block 8, and is processed by an electric discharge phenomenon.
- the wire electrode 6 In order to start processing, the wire electrode 6 needs to be connected to the collecting unit roller 10, and this connection operation is performed by a human hand or an automatic connection (not shown) provided in the wire electric discharge machine 100. Done by the device.
- the automatic wire connection device is a device for automatically connecting the wire electrode 6 passed to near the front of the upper guide block 7 to the collecting portion roller 10 through the lower guide block 8 and the lower roller 9.
- the wire electrode 6 can be automatically connected when the wire electrode 6 is disconnected, and the operation can be continuously performed even if the operator is not always in front of the machine.
- the automatic connection device During the operation of the automatic connection device, it is necessary to feed the wire electrode 6 by the tension setting roller 1 or the like and insert the tip of the wire electrode 6 coming out of the upper guide block 7 into the entrance of the lower guide block 8.
- the wire electrode 6 wound and supplied to the wire hobbin is bent, that is, curled, so-called curl, and the tip of the wire electrode 6 is deviated from the outlet of the upper guide block 7 as it is. It is difficult to lead to 8 entrances. Therefore, in order to reliably guide the curled wire electrode 6 to the entrance of the lower guide block 8, a jet of fluid is ejected from the exit of the upper guide block 7 to straighten the wire electrode 6 or is called annealing treatment.
- a method of taking the wire electrode 6 to be straightened by applying a heat treatment to the wire electrode 6 is adopted.
- Annealing is a process also called annealing.
- the wire electrode 6 is wound around the wire hobbin or bent while being fed by a roller, so that strain is accumulated inside the wire electrode 6, thereby causing bending wrinkles.
- the material of the wire electrode 6 that is often used is brass.
- the distortion accumulated in the brass is corrected by heating and straightened.
- a current is passed from the heating power supply device 85 to the wire electrode 6 between the first annealing electrode 2 and the second annealing electrode 4 brought into contact with the wire electrode 6 to generate Joule heat due to the resistance value of the wire electrode 6. Is heated. During heating, the wire electrode 6 is stretched due to thermal expansion of the brass.
- the wire electrode 6 is sandwiched and fixed by the pinch roller 5 so that the wire electrode 6 does not bend due to this elongation.
- the tension is set by the tension setting roller 1. Further, in order to make the wire electrode 6 thin and facilitate insertion, the wire electrode 6 being heated is tensioned and stretched.
- a current is supplied to the wire electrode 6 between the first cutting electrode 3 and the second annealing electrode 4 (also serving as the second cutting electrode) 4 to melt the wire electrode 6.
- the wire straightened by the annealing process in this manner is processed after the upper guide block 7 through the upper guide block 7 after the tip of the cut wire electrode 6 remaining in the upper guide block 7 is removed by a wire recovery mechanism (not shown). It passes through the hole or groove in the object and is inserted into the lower guide block 8.
- the amount of current and the time to be energized during the annealing process are determined depending on what temperature the wire electrode 6 is heated to. If the temperature rise of the wire electrode 6 due to heating is not sufficient, the distortion is not sufficiently removed, and the straightness of the resulting wire is not good. Also, if the temperature is too high, the elastic limit, hardness, and mechanical strength of the wire electrode 6 are reduced, so that the force to send out the wire electrode 6 cannot be sufficiently transmitted, or when the wire electrode 6 is caught during insertion. This causes a problem that the wire electrode 6 is bent. Further, if the amount of current is excessive, the wire electrode 6 may be melted.
- the value of the amount of heat Q [J] supplied to the wire electrode 6 represents the specific resistance of the wire electrode 6 as ⁇ [ ⁇ ⁇ m], the cross-sectional area is A [m 2 ], the length is L [m], the energization current amount is i [A], and the energization time is t [s].
- the temperature rise T [K] of the wire electrode 6 due to heating is based on the relationship between the amount of heat and the specific heat.
- the value of the temperature rise obtained from this equation is based on the relationship between the amount of heat and the specific heat.
- the heat of the wire electrode 6 is heat conduction to the contact portion of the first annealing electrode 2 and the second annealing electrode 4, heat transfer to the atmosphere, and heat radiation that is heat dissipation by electromagnetic waves. Because it will be lost.
- the diameter of the wire electrode 6 that is generally used is as thin as 0.3 [mm] or less, the ratio of the surface area to the volume is large and the degree of heat dissipation is large. The dissipation of heat is also affected by the temperature and wind in the surrounding environment where the wire electrode 6 is heated. For these reasons, it is difficult to accurately estimate the temperature rise of the wire electrode 6 from the relationship between the amount of heat applied to the wire electrode 6 and the heat capacity.
- the temperature of the wire electrode 6 increases in proportion to the time, but in reality, the amount of heat supplied to the wire electrode 6 and the escape from the wire electrode 6.
- the rise in the temperature of the wire electrode 6 stops at a temperature at which the amount of heat generated is balanced. If this is used, an excessive temperature rise can be prevented by setting a constant current value during annealing, but it takes time for the temperature to rise and become constant, so it is necessary for the annealing process. It will take a long time.
- a method for directly measuring the temperature of the wire electrode 6 is required in order to keep the temperature of the wire electrode 6 appropriately during annealing.
- a contact-type temperature sensor such as a thermocouple or a non-contact temperature sensor such as a radiation temperature sensor is used.
- a contact-type temperature sensor since the heat capacity of the wire electrode 6 itself is very small, an increase in temperature is affected by the heat capacity of the temperature sensor, and it is difficult to accurately measure the temperature.
- a non-contact type temperature sensor when used, the temperature can be measured without affecting the wire electrode 6, but the apparatus is relatively expensive and the wire electrode 6 has a small diameter. For this reason, it is difficult to use it by incorporating it into an electric discharge machine because a sufficient amount of heat radiation cannot be obtained.
- the annealing method of the present embodiment proposes a method that can easily estimate the temperature rise of the wire electrode 6.
- the heating power supply device 85 that heats the wire electrode 6 includes a current value energized to the wire electrode 6 during the annealing process and a current-voltage measuring unit 75 for measuring the voltage value at that time. Is provided.
- the measured information can be sent to the control device 80.
- the control device 80 calculates the load resistance value r [ ⁇ ] of the power supply device from the obtained voltage value v [V] and current value i [A] by the following calculation.
- the calculation of the resistance value can be performed at any time. However, when the current is not flowing, the resistance value is divided by 0, and the value becomes infinite.
- the temperature rise and the increase in the resistance value may not coincide with the temperature coefficient specific to the material of the wire. Many. This is because, in addition to the resistance value of the wire, the load resistance value obtained by the equation (3) includes the contact resistance between the wire and the wire electrode, the wiring of the current voltage measuring unit and the heating power supply device. This is thought to be due to the inclusion of resistance.
- the resistance of a brass wire with a wire length of about several tens of centimeters and a diameter of 0.1 to 0.33 mm is 0.1 to several ⁇ , so contact resistance and wiring resistance are 0.1 to It can be seen that even a value of about 1 ⁇ has a greater effect than the resistance value of the wire.
- the contact state is not constant. Further, since the wire diameter may change or dirt or oxide may adhere to the surface of the wire or heating electrode, the contact state is considered to change every time annealing is performed.
- the temperature coefficient ⁇ 0 is different from the value of R C and R L included in the denominator. Furthermore, R W is changed each time the annealing, since the value is large, it is difficult to eliminate the influence by the like to correct the predetermined value is in the estimation result of the temperature.
- an accurate wire temperature rise value is calculated by the following method.
- FIG. 2 is a sequence diagram showing an example of the procedure of the annealing process of the present embodiment.
- the theoretical resistance value Rideal [ ⁇ ] of the wire electrode 6 stretched between the annealing electrodes 2 and 4 is calculated (step S11). This can be calculated from the material of the wire electrode 6 to be used, the wire diameter, and the length between the annealing electrodes. For example, when the material of the wire electrode 6 is brass, the specific resistance value is about 6.3 ⁇ 10 ⁇ 8 [ ⁇ ⁇ m]. If the wire diameter is 0.2 [mm] and the length is 250 [mm], the theoretical resistance value is about 0.5 [ ⁇ ].
- the theoretical resistance value of the wire electrode 6 is not calculated every time, and the wire target temperature may be selected from a list of values calculated or measured in advance (step S12). Similarly, the value of the specific resistance may be selected from a list according to the type of the wire electrode 6. This calculation is equivalent to obtaining the value of the resistance RW of the wire electrode itself described in the above explanation.
- Rinit [ ⁇ ] is recorded from the current and voltage values immediately after the start of energization (at the start of heating) (step S13). Since the contact resistance value of the wire seems to change every time annealing is performed, Rinit is calculated and recorded every time annealing is performed. Since the temperature of the wire electrode 6 is considered to be almost the same as the room temperature immediately after the start of energization, this is the resistance value at room temperature. Subsequently, the current resistance value R [ ⁇ ] is calculated from the current and voltage values (step S14), and the resistance value increment dR [%] is calculated from these values using the following equation (step S14). S15). Rinit and R include the resistance value of the wire to the annealing electrodes 2 and 4 and the contact resistance between the annealing electrodes 2 and 4 and the wire electrode 6 in addition to the resistance value of the wire electrode.
- R-Rinit represents a resistance value increase amount in the wire electrode 6 among the calculated resistance values.
- the resistance value R calculated from the current and voltage values includes the power supply voltage other than the resistance value of the wire electrode 6 itself. This is to prevent the value of dR from accurately representing the temperature rise of the wire electrode 6 because the wiring from the electrode to the electrode, the contact resistance between the wire electrode 6 and the electrode, and the like are included.
- the resistance value Rbase from the power source to the wire electrode is measured in advance, You may calculate using.
- the contact resistance includes the influence that varies depending on the wire diameter, wire type, and annealing treatment trial of the wire electrode, the accuracy is lowered.
- the specific resistance of the conductor varies with temperature and increases. For this reason, the calculated value of dR also increases as the temperature of the wire electrode 6 rises due to energization.
- the specific resistance of 65/35 brass as cold-worked 22.4% is a temperature of about 7.5 ⁇ 10 ⁇ 11 [ ⁇ ⁇ m / ° C.].
- the coefficient ⁇ has a value of 7.4 ⁇ 10 ⁇ 8 + ⁇ (T ⁇ 20) with respect to the temperature T ° C. when the value is about 20 ° C. Accordingly, the resistance value changes by about 0.1 [% / ° C.].
- the value of dR / 0.1 + room temperature can be regarded as the wire temperature.
- the specific resistance and the temperature coefficient of the specific resistance can be selected in accordance with the type of the wire electrode 6, so that the temperature can be estimated for various wire electrodes 6 (step S16). Then, for example, the current or voltage is adjusted from the difference between the target temperature and the estimated temperature (step S17). This is repeated until the annealing process (heating process) is completed (step S18).
- the energization is terminated when the target temperature is reached to prevent the temperature from rising excessively, or conversely during the annealing process. It becomes possible to detect that the wire electrode 6 has not reached the target temperature due to insufficient current amount or excessive cooling from the surroundings. Further, by changing the current amount during the annealing process, for example, immediately after the start of energization, a large amount of current is passed to increase the heating amount, and the time required for the wire electrode 6 to reach the target temperature can be shortened. As shown in the annealing processing sequence shown in FIG.
- the current amount is adjusted and the constant temperature is maintained for a predetermined time. It becomes possible. As a result, reliable annealing can be performed even under conditions where there is disturbance from the surrounding environment such as wind, and the strength of the wire electrode 6 can be improved by improving the straightness of the wire electrode 6 and excessively increasing the temperature. Effects such as prevention of loss of heat and shortening of annealing time can be achieved.
- the current value and voltage value from the heating power supply device 85 that heats the wire electrode 6 by energization are measured, and the measured current value is used.
- the load resistance value is calculated by dividing the voltage value, and the resistance of the wire electrode is calculated from the amount of increase in the load resistance value based on the load resistance value immediately after the start of heating and the estimated resistance value of the wire electrode itself at room temperature.
- the value increment is calculated, the temperature increase value of the wire electrode is estimated based on the preset specific resistance of the wire electrode and the temperature coefficient of the specific resistance, and the energization state to the wire electrode is controlled based on the estimated temperature increase value .
- the heating power supply device 85 that heats the wire electrode 6 by supplying power, and the current value and voltage value that are passed through the wire electrode 6 are measured.
- the load resistance value is calculated by dividing the voltage value by the measured current value and the measured current value, and the increase amount of the load resistance value based on the load resistance value immediately after the start of heating is estimated.
- the resistance value increment of the wire electrode 6 is calculated from the resistance value of the wire electrode 6 itself at normal temperature, and the temperature rise value of the wire electrode 6 is estimated based on the specific resistance of the wire electrode 6 and the temperature coefficient of the specific resistance set in advance.
- a control unit 70 that controls the energization state of the wire electrode 6 based on the estimated temperature rise value.
- the temperature of the wire electrode 6 during the annealing process can be accurately detected, and the annealing process is performed at an appropriate temperature. Therefore, the wire electrode with a bent crease can be easily straightened, and the time required for the annealing process can be reduced. It becomes possible to shorten.
- Embodiment 2 When the wire electrode 6 is annealed, thermal expansion occurs as the temperature of the wire electrode 6 rises, and the wire electrode 6 extends and sagging occurs. When annealing is performed in a slack state, sufficient straightening is not achieved. Therefore, when annealing is performed, it is necessary to apply tension to the wire electrode 6 and pull the wire electrode 6 to keep it straight. For example, in FIG. 1, the wire electrode 6 is sandwiched and fixed by a pinch roller 5 and tension is applied to the wire electrode 6 by the tension setting roller 1. Further, the wire electrode 6 is pulled and extended to improve straightness, or to make it thin so that the hole can be easily passed through.
- the resistance value R ′ of the wire electrode 6 after stretching is expressed by the following equation.
- the length of the wire electrode 6 is extended to ⁇ L, but the resistance value in question here is the resistance value of the wire electrode 6 between the first and second annealing electrodes 2, 4.
- the length used for is still L.
- the resistance value R before stretching is Therefore, R ′ is expressed as follows using R.
- the resistance value is also increased by a factor of ⁇ .
- how much the wire electrode 6 has been extended can be measured by how much the tension setting roller 1 has rotated.
- the increase in resistance of the wire electrode 6 calculated from the current and voltage values of the heating power source includes an increase in resistance corresponding to the amount of elongation in addition to an increase in specific resistance. .
- the temperature rise can be detected more accurately. it can.
- the temperature may be estimated using a value obtained by dividing dR by 1.05.
- the tension is set for the wire electrode 6 during the annealing process, the elongation of the wire electrode 6 during the annealing process is detected, and the detected elongation is detected.
- the reduction of the cross-sectional area of the wire electrode 6 is estimated based on the amount, the increase amount of the resistance value of the wire electrode 6 is calculated based on this, and the estimated value of the temperature of the wire electrode 6 is corrected using this increase amount. I do. Therefore, by estimating the increase in the resistance value due to the elongation of the wire electrode 6 and removing this increase from the increase due to the temperature, the temperature estimation due to the increase in the resistance value can be performed more accurately.
- Embodiment 3 Although the wire electrode 6 is thermally stretched due to thermal expansion during heating, this value can be calculated from the expansion coefficient.
- the expansion coefficient of brass is about 1.8 ⁇ 10 ⁇ 5 [1 / ° C.]
- the thermal elongation is about 0.18% per 100 ° C. temperature rise.
- the amount of elongation of the wire electrode 6 when the wire electrode 6 is pulled by the tension setting roller 1 so that the wire electrode 6 does not sag during the annealing process, the amount of elongation of the wire electrode 6 from the rotation amount of the tension setting roller 1
- the amount of elongation is the heat generated as a result of the temperature rise of the wire electrode 6 due to heating. Elongation is included.
- the amount of elongation that has occurred is all handled as plastic deformation caused by stretching, but in reality, the amount of thermal elongation is also included, and if all are treated as plastic deformation by stretching, the wire diameter becomes excessively thin. Under such an assumption, there is a possibility that the resistance value R ′ is calculated to be larger.
- FIG. 3 is a diagram showing an example of an annealing process sequence in the case of performing correction based on wire elongation.
- symbol is attached
- the resistance value R ′ is calculated as plastic deformation caused by stretching all the measured elongation, and the estimated value of temperature is calculated from dR based on this value.
- step S21 the amount of thermal elongation at the estimated temperature is calculated (step S21), and the elongation value obtained by subtracting the amount of thermal elongation from the measured amount of elongation of the wire electrode 6 is used (step S22).
- step S23 calculates dR based on this value, and recalculate the estimated temperature value (step S24). This calculation may be repeated until the estimated temperature value does not change to some extent (step S25). This enables more accurate temperature estimation.
- the elongation due to the thermal expansion of the wire electrode 6 is calculated from the estimated temperature of the wire electrode 6, the length of the elongation due to the thermal expansion is reduced from the amount of elongation during the annealing treatment, and then the wire electrode Since the resistance increase due to the elongation of the wire electrode 6 is corrected, when the resistance value increase due to the elongation of the wire electrode 6 is corrected, only the elongation due to the tension is used to correct the temperature increase except for the thermal elongation of the wire electrode 6. As a result, the accuracy of temperature rise estimation can be increased.
- Embodiment 4 The specific resistance and the value of the temperature coefficient of the specific resistance represent the resistance value of an object under a certain temperature and how much the resistance value changes with temperature. Since this is a value for an object having a certain volume, it is considered to be a value including a shape change such as expansion and elongation due to a temperature change.
- the wire electrode 6 to be heated expands by heating, but the distance between the electrodes for supplying the current for heating to the wire electrode 6 is fixed to the machine body. For this reason, it is general that it is constant and does not follow the elongation due to heating.
- the end of the wire electrode 6 gradually deviates from the section where current is applied.
- the resistance value of the wire electrode is measured from the voltage and current between the electrodes, the length of the wire electrode 6 measured after the temperature rises is almost close to normal temperature immediately after heating. That is, the length shorter than the wire electrode 6 measured in step 1 by the amount of thermal elongation is measured. If the fact that the length of the wire electrode 6 actually measured due to thermal elongation is not taken into consideration is taken into account is taken into account, the increase in the resistance value is calculated to be small, and as a result, the temperature rise is estimated to be small.
- the thermal elongation amount of the wire electrode 6 is estimated from the temperature and the expansion coefficient of the wire electrode material, and this thermal elongation amount is used.
- the resistance value R of the wire electrode 6 may be corrected. For example, in the case of a brass wire electrode, if the temperature rises by 200 ° C., the wire length is considered to increase by about 0.36%, so the value obtained by adding the resistance value for 0.36% to the calculated resistance value R is the original value. It is considered to be a resistance value.
- the dR may be calculated using the resistance value Rideal of the reference wire electrode 6 or a value obtained by subtracting the Rinit-Rbase value by the amount of elongation.
- Rinit includes a contact resistance and a wiring resistance in addition to the resistance value of the wire electrode 6, it is not possible to correct the amount corresponding to the elongation.
- the amount of thermal elongation due to the temperature rise of the wire electrode 6 is estimated based on the estimated temperature of the wire electrode 6 and a preset expansion coefficient, and the wire estimated based on the value of this thermal elongation amount Since the increment of the resistance value of the electrode 6 is corrected, it is possible to estimate the temperature more accurately by correcting that the length of the wire electrode for measuring the resistance is substantially shortened due to the thermal elongation of the wire electrode 6.
- Embodiment 5 FIG.
- the brass wire electrode includes a relatively soft material called a soft wire in addition to a commonly used wire (hard wire). The difference between the two is caused by the difference in heat treatment after wire drawing.
- FIG. 53 of the said nonpatent literature 1 is seen, in the brass which annealed as it was cold processing, even if it is the same composition, it is shown that an electrical resistance (specific resistance) differs.
- the value of the annealed material is almost the same, but in the case of cold working, the electrical resistance value is larger than that of the annealed material, and the temperature coefficient value is small.
- both values approach as the temperature rises and are expected to match around 400 ° C. The reason why both values approach is that it is considered that raising the temperature of the cold worked product has a meaning close to that of annealing.
- the values of specific resistance and temperature coefficient to be used are different, and in the case of a hard wire, the cold working remains
- the value after annealing is used, and the temperature can be estimated as described above.
- the annealing method according to the present invention is useful for the annealing method of a wire electric discharge machine for processing a workpiece by generating an electric discharge phenomenon between the workpiece and the wire electrode, Wire electrical discharge machining that arranges a pair of electrodes at two predetermined points of the wire electrode and applies a current through the electrode in a state where tension is applied to the wire electrode to heat the wire electrode to correct the bending wrinkle between the two points. Suitable for machine annealing method.
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Abstract
Description
図1は、本発明にかかるワイヤ放電加工機の実施の形態1の構成を示す図である。ワイヤ放電加工機100は、図1に示すように、ワイヤ電極6の経路に沿って、テンション設定ローラ1、第1アニール用電極2、第1切断用電極3、第2アニール用電極(第2切断用電極を兼ねる)4、ピンチローラ5、上部ガイドブロック7、下部ガイドブロック8、下部ローラ9、及び回収部ローラ10がこの順序で装備されている。
R = R0{1+α0(t-t0)}
ここで、RおよびR0はそれぞれ温度tおよびt0での抵抗値、α0[1/℃]は抵抗値に対する温度係数である。この式を変形すると以下の数式(a)のようになる。
(R-R0)/R0 = α0(t-t0) …数式(a)
即ち、抵抗値RとR0、および温度係数α0が分かれば、温度の変化 t-t0 が分かることになる。
R0 = RW + RC+ RL、R = RW + dr + RC+ RL …数式(b)
と考えられるから、負荷抵抗を用いて温度上昇を推定する場合、数式(a)の左辺は、{(RW + dr + RC + RL) - (RW+ RC + RL)} / (RW + RC + RL)= dr / (RW + RC + RL) となる。即ち、分母に含まれる RC や RL の値の分だけ温度係数α0と差異が生じることになる。さらに、RWはアニールをおこなう度に変化し、値も大きいため、温度の推定結果に有る一定値の補正をおこなうなどをして影響を取り除くことは難しい。
(R-Rideal)/Rideal
によって数式(a)の左辺を算出することも考えられる。しかし、実際にはこの方法では十分に精度を高めることは出来ない。なぜならば、R= RW + dr + RC + RL であり、Rideal = RW とすると、
(R-Rideal)/Rideal= (dr + RC + RL)/ RW
となるため、数式(a)からワイヤ温度上昇を算出する際に接触抵抗や配線抵抗の影響を受けることになるためである。
ワイヤ電極6のアニール処理の際には、ワイヤ電極6の温度上昇に伴って熱膨張が生じ、ワイヤ電極6が伸びてたるみが生じる。たるんだ状態でアニール処理を行うと十分な真直化が為されないため、アニールを行う際にはワイヤ電極6にテンションを与えて引っ張り、常に真っ直ぐな状態に保つ必要がある。これは、例えば図1中で、ワイヤ電極6をピンチローラ5で挟んで固定し、テンション設定ローラ1によってワイヤ電極6へテンションをかけることによって行われる。更に、ワイヤ電極6を引っ張って延ばし、真直性を高めたり、細くして穴を通しやすくしたりする等の処理が行われる。
加熱時には熱膨張によってワイヤ電極6に熱伸びが生じているが、この値は膨張率から算出できる。例えば黄銅の膨張率は約1.8×10-5[1/℃]であり、100℃の温度上昇につき約0.18%の熱伸びとなる。実施の形態2において、アニール処理中にワイヤ電極6のたるみを生じない様にテンション設定ローラ1でワイヤ電極6を引っ張っている際に、テンション設定ローラ1の回転量からワイヤ電極6の伸びの量を知ることができるが、この伸びの量にはワイヤ電極6への張力によってワイヤ電極6を引き伸ばし、塑性変形をさせた伸び量の他に、ワイヤ電極6が加熱によって温度上昇した結果生じた熱伸びが含まれている。実施の形態2では、生じた伸びの量をすべて引き伸ばしによって生じた塑性変形として扱ったが、実際には熱伸び量も含まれており、すべて引き伸ばしによる塑性変形として扱うと過剰に線径が細くなったという仮定の下で、より抵抗値R’を大きく算出してしまう可能性がある。
比抵抗や比抵抗の温度係数の値は、ある温度下の物体の抵抗値や、その抵抗値が温度に対してどれだけ変化するかということを表している。これは、ある体積をもった物体に対しての値であるので、温度変化による膨張、伸びといった形状変化を含んだ値と考えられる。一方、ワイヤ放電加工機100においては、加熱対象であるワイヤ電極6は加熱によって伸張するが、加熱を行うための電流をワイヤ電極6へ通電する電極間の距離は加工機本体に固定されているために一定で、加熱による伸びには追従しないことが一般的である。このため、加熱の際にワイヤ電極6に熱伸びが生じると、ワイヤ電極6の端部は通電を行う区間から徐々に外れていく事になる。実施の形態1で述べた様に、電極間の電圧と電流からワイヤ電極の抵抗値を測る場合、温度が上昇してから計測したワイヤ電極6の長さは、加熱直後のほぼ常温に近い状態で計測したワイヤ電極6よりも熱伸びの分だけ短い長さを計測した事になる。もし熱伸びによって実際に計測しているワイヤ電極6の長さが短くなることを考慮しない場合、抵抗値の増加が少なめに算出され、結果、温度上昇が少なく見積もられる。
黄銅ワイヤ電極には一般的によく使用されるワイヤ(ハードワイヤ)の他に、ソフトワイヤと呼ばれる比較的柔らかいものがある。両者の差は伸線加工後の熱処理の差によって生じる。上記非特許文献1の図53をみると、冷間加工のままと焼き鈍しをおこなった黄銅では、同一組成でも電気抵抗(比抵抗)が異なることが示されている。また、焼き鈍しを行ったものの値はほぼ同じであるのに対し、冷間加工のままの場合には、電気抵抗の値は焼き鈍しされたものより大きく、かつ、温度係数の値は小さいことが分かる。さらに、両者の値は温度が上昇するにつれて近づいて行き、およそ400℃付近で一致すると予想される。両者の値が近づくのは、冷間加工のままのものの温度を上げることは、焼き鈍しを施していることに近い意味を持つためと考えられる。
2 第1アニール用電極
3 第1切断用電極
4 第2アニール用電極(第2切断用電極を兼ねる)
5 ピンチローラ
6 ワイヤ電極
7 上部ガイドブロック
8 下部ガイドブロック
9 下部ローラ
10 回収部ローラ
60 記憶部
65 推定部
70 制御部
75 電流電圧測定部
80 制御装置
85 加熱用電源装置
100 ワイヤ放電加工機
Claims (8)
- 工作物とワイヤ電極との間に放電現象を発生させて工作物の加工を行うワイヤ放電加工機の、前記ワイヤ電極の所定の2点に一対のアニール用電極を配置し、前記ワイヤ電極に張力を与えた状態で前記アニール用電極を介して電流を流し前記ワイヤ電極を加熱して、前記2点間の曲がり癖を矯正するワイヤ放電加工機のアニール処理方法において、
前記ワイヤ電極に通電することによって加熱する加熱用電源装置からの電流値と電圧値を計測し、計測した電流値で電圧値を除することで負荷抵抗値を計算し、加熱開始直後の負荷抵抗値を基準とした負荷抵抗値の増加量と、前記ワイヤ電極自体の常温での抵抗値から前記ワイヤ電極の抵抗値増分を計算し、予め設定した前記ワイヤ電極の比抵抗及び比抵抗の温度係数に基づいて前記ワイヤ電極の温度上昇値を推定し、
推定した温度上昇値に基づいて前記ワイヤ電極への通電状態を制御する
ことを特徴とするワイヤ電極アニール処理方法。 - 加熱開始直後の負荷抵抗値Rinit、加熱中の負荷抵抗値R、およびワイヤ電極自体の常温での理論抵抗値Ridealに基づいて、(R-Rinit)をRidealで除した比率を前記ワイヤ電極の抵抗値増分として用いる
ことを特徴とする請求項1に記載のワイヤ電極アニール処理方法。 - 加熱開始直後の負荷抵抗値Rinit、加熱中の負荷抵抗値R、および予め決定しておいた配線の抵抗値Rbaseに基づいて、(R-Rinit)を(Rinit-Rbase)で除した比率を前記ワイヤ電極の抵抗値増分として用いる
ことを特徴とする請求項1に記載のワイヤ電極アニール処理方法。 - アニール処理中の前記ワイヤ電極に対して張力を設定し、アニール処理時の前記ワイヤ電極の伸びを検知し、検知した伸び量に基づいてワイヤ電極の断面積の減少を推定し、これに基づいた前記ワイヤ電極の抵抗値の増加量を算出し、この増加量を用いて、ワイヤ電極の温度の推定値の補正を行う
ことを特徴とする請求項1に記載のワイヤ電極アニール処理方法。 - 推定した前記ワイヤ電極の温度からワイヤ電極の熱膨張による伸びを算出し、その熱膨張による伸びの長さをアニール処理時の伸び量より減じてから、ワイヤ電極の伸びによる抵抗増加の補正を行う
ことを特徴とする請求項4に記載のワイヤ電極アニール処理方法。 - 推定した前記ワイヤ電極の温度と予め設定した膨張率を基にワイヤ電極の温度上昇による熱伸び量を推定し、この熱伸び量の値を基に推定した前記ワイヤ電極の抵抗値増分を補正する
ことを特徴とした請求項1に記載のワイヤ電極アニール処理方法。 - 前記ワイヤ電極として黄銅を用いる際、ハードワイヤとソフトワイヤとで用いる比抵抗と温度係数の値を別にし、ハードワイヤの場合は冷間加工のままの場合の値を用い、ソフトワイヤの場合は焼き鈍し後の値を用いるとともに、ハードワイヤを使用する際は、推定温度が350℃~450℃の範囲のいずれかで、用いる比抵抗の温度係数の値を焼き鈍し後の値に切り替える
ことを特徴とした請求項1から6のいずれか1項に記載のワイヤ電極アニール処理方法。 - 工作物とワイヤ電極との間に放電現象を発生させて工作物の加工を行うとともに、前記ワイヤ電極の所定の2点に一対のアニール用電極を配置し、前記ワイヤ電極に張力を与えた状態で前記アニール用電極を介して電流を流し前記ワイヤ電極を加熱して、前記ワイヤ電極の前記2点間の曲がり癖を矯正するワイヤ放電加工機において、
前記ワイヤ電極に電力を供給することによって加熱する加熱用電源装置と、
前記ワイヤ電極に通電する前記加熱用電源装置からの電流値と電圧値を計測する電流電圧測定部と、
計測した電流値で電圧値を除することで負荷抵抗値を計算し、加熱開始直後の負荷抵抗値を基準とした負荷抵抗値の増加量と、前記ワイヤ電極自体の常温での抵抗値とから前記ワイヤ電極の抵抗値増分を計算し、予め設定したワイヤ電極の比抵抗及び比抵抗の温度係数に基づいて前記ワイヤ電極の温度上昇値を推定する推定部と、
推定した温度上昇値に基づいて前記ワイヤ電極への通電状態を制御する制御部と、
を備えたことを特徴とするワイヤ放電加工機。
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JPS54141490A (en) * | 1978-04-27 | 1979-11-02 | Mitsubishi Electric Corp | Wire-cut electric discharge machining method and device |
JPH054125A (ja) * | 1991-06-28 | 1993-01-14 | Furukawa Electric Co Ltd:The | ワイヤ放電加工機 |
JPH05177443A (ja) * | 1991-12-27 | 1993-07-20 | Sumiden Fine Kondakuta Kk | 放電加工用電極線の製造方法 |
JP2000094225A (ja) * | 1998-09-22 | 2000-04-04 | Seibu Electric & Mach Co Ltd | ワイヤ放電加工機 |
JP2003094253A (ja) * | 2001-09-27 | 2003-04-03 | Brother Ind Ltd | ワイヤ放電加工機、ワイヤ放電加工機の制御方法およびワイヤ放電加工機制御用プログラム |
JP2003094254A (ja) * | 2001-09-27 | 2003-04-03 | Brother Ind Ltd | ワイヤ放電加工機およびアニール処理方法 |
Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
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JP5950265B1 (ja) * | 2015-10-11 | 2016-07-13 | マグネデザイン株式会社 | 磁性ワイヤ熱処理装置および磁性ワイヤ熱処理方法 |
JP2017071846A (ja) * | 2015-10-11 | 2017-04-13 | マグネデザイン株式会社 | 磁性ワイヤ熱処理装置および磁性ワイヤ熱処理方法 |
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JPWO2012067078A1 (ja) | 2014-05-12 |
BR112013010369A2 (pt) | 2017-10-10 |
US9433035B2 (en) | 2016-08-30 |
CN103209796B (zh) | 2015-04-29 |
JP5474214B2 (ja) | 2014-04-16 |
DE112011103824B4 (de) | 2022-12-15 |
DE112011103824T5 (de) | 2013-08-14 |
US20130334187A1 (en) | 2013-12-19 |
CN103209796A (zh) | 2013-07-17 |
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