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中走丝处理方法

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中走丝处理方法

发布日期:2016-04-21 00:00 来源:http://tianxialiushui.cn 点击:

对于线切(qie)割(ge)(ge)(ge)工(gong)(gong)(gong)(gong)(gong)件余(yu)留(liu)(liu)(liu)部(bu)位(wei)切(qie)割(ge)(ge)(ge)的(de)多次(ci)加工(gong)(gong)(gong)(gong)(gong),首先必须解决被加工(gong)(gong)(gong)(gong)(gong)工(gong)(gong)(gong)(gong)(gong)件的(de)导电(dian)问(wen)题,因(yin)为(wei)在(zai)高(gao)精(jing)度线切(qie)割(ge)(ge)(ge)加工(gong)(gong)(gong)(gong)(gong)中,线电(dian)极的(de)行(xing)(xing)走路线可能需要沿加工(gong)(gong)(gong)(gong)(gong)轨迹往(wang)复(fu)行(xing)(xing)走多次(ci),才能保(bao)证被加工(gong)(gong)(gong)(gong)(gong)工(gong)(gong)(gong)(gong)(gong)件具有(you)较高(gao)表(biao)面粗糙度和表(biao)面精(jing)度,这时线切(qie)割(ge)(ge)(ge)加工(gong)(gong)(gong)(gong)(gong)是(shi)靠(kao)工(gong)(gong)(gong)(gong)(gong)件余(yu)留(liu)(liu)(liu)部(bu)位(wei)起到导电(dian)作用(yong)以保(bao)障电(dian)加工(gong)(gong)(gong)(gong)(gong)正常(chang)进(jin)行(xing)(xing)。但在(zai)进(jin)行(xing)(xing)工(gong)(gong)(gong)(gong)(gong)件余(yu)留(liu)(liu)(liu)部(bu)位(wei)的(de)切(qie)割(ge)(ge)(ge)加工(gong)(gong)(gong)(gong)(gong)时,若第一次(ci)切(qie)割(ge)(ge)(ge)即切(qie)下工(gong)(gong)(gong)(gong)(gong)件余(yu)留(liu)(liu)(liu)部(bu)位(wei),将会导致被切(qie)割(ge)(ge)(ge)部(bu)分(fen)与(yu)母体分(fen)离,以致导电(dian)回路中断(duan),无(wu)法进(jin)行(xing)(xing)继续加工(gong)(gong)(gong)(gong)(gong),所以从(cong)线切(qie)割(ge)(ge)(ge)加工(gong)(gong)(gong)(gong)(gong)的(de)条(tiao)件性和延续性考(kao)虑(lv),必须使工(gong)(gong)(gong)(gong)(gong)件余(yu)留(liu)(liu)(liu)部(bu)位(wei)即便在(zai)多次(ci)切(qie)割(ge)(ge)(ge)的(de)情况下也能保(bao)持(chi)与(yu)母体之间正常(chang)导电(dian)的(de)要求。

为(wei)(wei)了(le)实现上述(shu)目的(de),操(cao)作工(gong)人力(li)图营(ying)造人为(wei)(wei)环境(jing)和(he)条(tiao)件(jian)来(lai)满足导(dao)电(dian)(dian)要(yao)求,即当工(gong)作人员在操(cao)作电(dian)(dian)火(huo)花线切(qie)割机遇到切(qie)割工(gong)件(jian)余留部位(wei)时(shi),可采用在被切(qie)割部分和(he)母体之间(jian)粘铜(tong)片和(he)在切(qie)割间(jian)隙中(zhong)塞铜(tong)片的(de)处(chu)理方法(fa)来(lai)造成人为(wei)(wei)的(de)定位(wei)条(tiao)件(jian)和(he)导(dao)电(dian)(dian)条(tiao)件(jian),使是火(huo)花加工(gong)得以继续进行,其具体做法(fa)与技巧(qiao)如下:

(1)在被(bei)切割(ge)部分与(yu)母体(ti)材料之间粘贴连接铜片。其目的是使工(gong)件余留部分在切割(ge)时与(yu)母体(ti)材料相连固(gu)定(ding),保(bao)证线切割(ge)有良好的定(ding)位条件,从(cong)而保(bao)障工(gong)件有优异(yi)的加工(gong)质量,这可依照(zhao)以下步骤进行:

①首先根据(ju)加工工件(jian)的大小把薄铜片(厚度根据(ju)线电(dian)极(ji)情况和加工部(bu)位形状而定)剪成长条形,然(ran)后折(zhe)叠(die),井保(bao)证折(zhe)叠(die)部(bu)分一(yi)长一(yi)短。

②然后(hou)把铜片折叠的(de)弯(wan)曲部分用(yong)小手锤锤平,并用(yong)什锦锉修(xiu)理成楔形;

③再(zai)把经以上处理(li)的铜(tong)片(pian)塞到(dao)线电极加工所形成的缝隙里,同时(shi)在工件该部分的表(biao)面滴(di)上502胶水(shui)(即环氧树脂(zhi)瞬时(shi)快干胶)。

由于切(qie)割时,电(dian)火花线切(qie)割机冲(chong)水(shui)使工(gong)件所受压力较(jiao)大(da),若单纯用铜(tong)片塞(sai)紧来保(bao)证导(dao)电(dian)和(he)固定(ding),容(rong)易产生(sheng)以下问题:(a)铜(tong)片塞(sai)得(de)太松,担(dan)心固定(ding)不可靠、导(dao)电(dian)不稳(wen)定(ding);(b)铜(tong)片塞(sai)得(de)太紧,又担(dan)心损(sun)伤(shang)工(gong)件表面、破坏形(xing)位公差,所以采(cai)用502胶(jiao)水(shui)来保(bao)证被切(qie)割部分与母体材料固定(ding);

④在将(jiang)铜(tong)片(pian)(pian)塞进(jin)加工(gong)部(bu)(bu)位时(shi),应(ying)注意是(shi):用502胶(jiao)水粘贴连(lian)接铜(tong)片(pian)(pian)时(shi)应(ying)远离工(gong)件余(yu)留部(bu)(bu)件处,以(yi)免502胶(jiao)水渗(shen)到,造成绝缘。此外粘贴连(lian)接铜(tong)片(pian)(pian)的(de)位置(zhi)应(ying)考虑对称分布,且(qie)应(ying)保(bao)证(zheng)同(tong)时(shi)塞紧(jin),避(bi)免工(gong)件发生偏移,以(yi)致影响(xiang)工(gong)件加工(gong)质(zhi)量。保(bao)证(zheng)被切割工(gong)件余(yu)留部(bu)(bu)位形状的(de)正确性和精(jing)度的(de)可靠性。

(2)在被(bei)切割部分与(yu)母体(ti)材料之间填(tian)(tian)充(chong)(chong)导(dao)(dao)(dao)电(dian)(dian)铜(tong)(tong)(tong)(tong)片(pian)(pian)(pian)。把(ba)经(jing)折叠、剪(jian)齐、锤平和修(xiu)锉的(de)(de)薄铜(tong)(tong)(tong)(tong)片(pian)(pian)(pian)填(tian)(tian)充(chong)(chong)在线电(dian)(dian)极加工(gong)形成的(de)(de)缝(feng)隙(xi)(xi)里,并使铜(tong)(tong)(tong)(tong)片(pian)(pian)(pian)和缝(feng)隙(xi)(xi)壁紧(jin)密贴合。填(tian)(tian)充(chong)(chong)此铜(tong)(tong)(tong)(tong)片(pian)(pian)(pian)的(de)(de)目(mu)的(de)(de)是(shi)(shi)为了(le)导(dao)(dao)(dao)电(dian)(dian),因为前面(mian)(mian)粘贴连接铜(tong)(tong)(tong)(tong)片(pian)(pian)(pian)时用了(le)502胶水(shui)(shui),而502胶水(shui)(shui)是(shi)(shi)不(bu)导(dao)(dao)(dao)电(dian)(dian)的(de)(de)。为了(le)实现导(dao)(dao)(dao)电(dian)(dian)要(yao)求,故采用填(tian)(tian)充(chong)(chong)导(dao)(dao)(dao)电(dian)(dian)铜(tong)(tong)(tong)(tong)片(pian)(pian)(pian)的(de)(de)方(fang)法,填(tian)(tian)充(chong)(chong)导(dao)(dao)(dao)电(dian)(dian)铜(tong)(tong)(tong)(tong)片(pian)(pian)(pian)时同(tong)(tong)样应注意铜(tong)(tong)(tong)(tong)片(pian)(pian)(pian)的(de)(de)对称(cheng)布置以及(ji)铜(tong)(tong)(tong)(tong)片(pian)(pian)(pian)应同(tong)(tong)时加紧(jin),并且(qie)不(bu)能(neng)塞得过紧(jin)以免划(hua)(hua)伤工(gong)件的(de)(de)表(biao)面(mian)(mian)。不(bu)管是(shi)(shi)粘贴连接铜(tong)(tong)(tong)(tong)片(pian)(pian)(pian)还是(shi)(shi)填(tian)(tian)充(chong)(chong)导(dao)(dao)(dao)电(dian)(dian)铜(tong)(tong)(tong)(tong)缝(feng)隙(xi)(xi)的(de)(de)形状。都应该(gai)把(ba)小铜(tong)(tong)(tong)(tong)片(pian)(pian)(pian)制成圆弧(hu)形,而且(qie)还应该(gai)用金(jin)相砂布打(da)磨被(bei)锤过的(de)(de)铜(tong)(tong)(tong)(tong)片(pian)(pian)(pian)表(biao)面(mian)(mian),以保证(zheng)铜(tong)(tong)(tong)(tong)片(pian)(pian)(pian)表(biao)面(mian)(mian)光滑以避免划(hua)(hua)伤工(gong)件已加工(gong)过的(de)(de)表(biao)面(mian)(mian)。

在采用电火花线切割机加工(gong)(gong)高硬度(du)、高精(jing)度(du)和(he)高复(fu)杂度(du)的(de)小型工(gong)(gong)件时,按照上述方法和(he)步骤进行(xing)线切割加工(gong)(gong)中工(gong)(gong)件余留部位的(de)精(jing)密(mi)切割,是一种行(xing)之有(you)效的(de)方法,它(ta)所提(ti)出的(de)步骤和(he)技巧,经济简便、实用可行(xing),从而为改(gai)善(shan)和(he)提(ti)高精(jing)密(mi)线切割加工(gong)(gong)的(de)质量和(he)效率探索出新的(de)途径。


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