Electrical discharge machining method of die inserted block for forming microstructure

Abstract

The invention relates to a method for manufacturing an electrode by adopting a multi-station combining method and machining a die inserted block for forming a microstructure by using the electrode, which belongs to the technical fields of special machining and micromachining. The method comprises two steps, i.e. combined electrode machining by electrical discharge wire-cutting and microstructure machining by electrical discharge forming. A plurality of discharge stations of which the narrow slit widths sequentially and gradually decrease are machined on the same electrode material by using the electrical discharge wire-cutting, the gradually-decreased values of the narrow slit widths are equivalent to the variable quantity of electrode scaling dimensions from rough machining to finish machining in the electrical discharge forming. When the electrical discharge forming is carried out, the positions of a workpiece and the electrode are exchanged, the polarity of a pulse power supply is reversed, and the workpiece carries out servo-feeding machining on the electrode so as to finish discharging machining on each station. The method provided by the invention has the effects and benefits that the error in repeatedly positioning caused by exchanging electrodes is avoided, the vibration error caused by the servo motion of an electrode with a heavier weight and a larger volume is avoided, both the manufactured micro inserted block and the manufactured microstructure are die steel and have high hardness, long service lives, good surface quality and mirror effects.

Description

technical field [0001] The invention belongs to the technical field of special processing and micro-processing, and relates to a method for manufacturing electrodes by using a multi-station combination method and using the electrodes to process mold inserts for forming microstructures. Background technique [0002] Injection molding and thermocompression molding technology, as the main technologies for mass production of microstructured plastic parts, have been increasingly widely used. Among them, the processing accuracy and quality of microstructured mold inserts are the key to forming microstructured plastic parts. Due to the local microstructure of this type of mold insert, strict requirements on shape and dimensional accuracy bring great difficulty to processing. If precision machining is used, there are difficulties in guaranteeing machining accuracy, low machining efficiency, and inability to process sharp-edged and acute-angled structures; while electron beam and ion...

AI Technical Summary

Problems solved by technology

If precision machining is used, there are difficulties in guaranteeing machining accuracy, low machining efficiency, and inability to process sharp-edged and acute-angled structures; while electron beam and ion beam machining need to be carried out under vacuum conditions, the practical application is limited; the shape accuracy of laser machining with generally poorer surface roughness

At present, the main technologies for making microstructure inserts are LIGA and UV-LIGA technologies, but these two technologies also have the following disadvantages: expensive, especially LIGA processing requires synchronous light sources; photolithography and electroforming processes are complex and difficult to operate Difficulty; electroforming layer materials are limited to copper, nickel and their alloys, low hardness, easy to damage, difficult to repair, short life

However, it can be known from the discharge mechanism of EDM that electrode loss is inevitable during the machining process. The electrode loss is more serious at the edge of the electrode because the tip discharge is easy; single-electrode continuous discharge machining often leads to a huge change in the shape of the electrode, and the processed workpiece Accuracy is difficult to guarantee; electrodes made of materials with high hardness and high melting point can only improve electrode loss to a certain extent

Therefore, electrode replacement is generally used to compensate for electrode loss, that is, the multi-electrode replacement method is used to improve machining accuracy, but the repeated positioning error caused by the multi-electrode replacement method makes this method difficult to apply in micromachining; and it is difficult to manufacture and repair electrodes online. Practical application is limited

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