3 Application of new technology of numerical control EDM
The EDM process is a direct means of achieving processing goals. At present, a variety of EDM processes have been developed and achieved certain economic benefits in production. The following describes several new processes and their advantages in CNC EDM.
3.1 Standardized fixtures for fast and precise positioning
CNC EDM is a standardized fixture that uses fast clamping to ensure extremely high repeatability and without reducing machining efficiency. There are currently EROWA in Switzerland and 3R devices in Sweden for fast and precise positioning. The principle of this type of device is that the electrode is manufactured at the same time, and the assembly of the collector and the clamp is completed on the same processing equipment as the process positioning reference attachment equipped with the numerical control electric discharge machine. The process positioning reference accessories are unified concentric and co-located, and each CNC machine tool has a coordinate origin. Therefore, after the electrode is manufactured, the components of the electrode and the clamp are directly removed and loaded into the reference accessory of the numerical control electric spark machine, and no correction adjustment is needed. If a “quick†machining is required during the machining process, the semi-finished product being processed can also be unloaded, and the rapid clamping process is continued after the emergency parts are processed. The standardized fixture is a fast and precise positioning process. Its use greatly reduces the clamping positioning time in the CNC EDM process and effectively enhances the competitiveness of the enterprise.
3.2 Mixing powder processing method to achieve mirror surface processing effect
A processing method in which a powder additive is mixed in an electric discharge machining liquid to obtain a glossy surface at a high speed is called a mixed powder processing. This method is mainly applied to complex mold cavities, especially precision machining of complex surfaces that are not convenient for polishing operations. It can reduce the surface roughness value of the parts, eliminate the manual polishing process, and improve the performance of the parts (such as life, wear resistance, corrosion resistance, mold release, etc.). The processing principle is mainly to add a certain proportion of conductive powder into the electric spark working fluid, the discharge gap is increased, the parasitic capacitance and current density between the electrodes are reduced; the discharge point dispersion and the discharge concentration phenomenon are reduced. The main technical requirements for the processing of mirrors by the mixing method are: EDM machines with mirror finishing circuits (with very small single pulse energy); selection of suitable powder additives; concentration management of powder additives; use of diffusion devices to eliminate concentration errors; No flushing treatment. The development of the mixed powder processing technology has made the mirror processing of precision cavity molds a reality.
3.3 shaking processing method to achieve high precision machining
When EDM machining complex cavity, the processing difficulty and processing area in different directions are very different, which will cause local concentration of machining chips, triggering unstable processing and uneven discharge gap. In order to ensure the uniformity of the discharge gap at high efficiency and maintain high stable processability, the method of continuously shaking the electrode can be used in the process. The method of shaking in the processing can obtain a more uniform surface roughness of the side and the bottom surface, and it is easier to control the processing size. The selection of the shaking processing is determined according to the shaking pattern of the processed portion, the shape of the shaking amount, and the accuracy. If the method of shaking is not used in the process, it is difficult to achieve stable processing under small gap discharge conditions. Unstable processing phenomena due to this cause are easily found in finishing, and the unstable discharge makes the size not accurately controlled and the roughness is uneven. The use of the shaking processing method can solve these problems well and ensure high-precision, high-quality machining.
3.4 Multi-axis linkage machining method to achieve complex machining
In recent years, with the development of the mold industry and computer technology, the advancement of multi-axis linkage EDM technology has been promoted. The multi-axis rotary system is combined with a variety of linear motions to form a variety of composite motion modes to meet the processing requirements of different types of workpieces. The processing range of CNC EDM is expanded, and its comparative advantages and technical benefits in precision machining are improved. . CNC EDM machine tools can easily realize the processing of complex cavity molds or tiny parts that are difficult to process in traditional EDM machines, such as three-dimensional spiral surface, fine gears, and fine racks. At present, the die-making enterprise adopts the axial servo machining of the formed electrode by the numerical control EDM, but it can also use the multi-axis linkage method to improve the processing performance. For example, the clear corner part adopts X, Y and Z in the case of feasible processing. The method of shaft linkage, that is, oblique processing, avoids the phenomenon that the discharge is unstable due to the small area of ​​the processing portion. The processing of the mold latent rubber mouth can also be performed by oblique multi-axis linkage processing by designing the positioning of the electrode inclination.
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