High-accuracy zinc base alloy electrode wire and preparing method thereof

Abstract

The invention relates to a high-accuracy zinc base alloy electrode wire. Components in a shell layer comprise, by weight, 70.5%-95% of Zn, 2.5%-27% of Cu, 0.02%-4.0% of X, 0.002%-0.4% of Y and inevitable impurities brought in by raw materials. X is any two kinds of metal from Ni, Ag, Cr, Si and Zr, the content ranges of the two kinds of metal are both 0.01%-2.0%, Y is any two kinds of elements of Ti, Al, Co, B and P, and the content range of the two elements are both 0.001%-0.2%. The epsilon phase content in the shell layer structure is over 80% by weight, the balance is a gamma phase or an eta phase, and epsilon phases are evenly distributed on the surface of core materials. Meanwhile, the invention relates to a preparing method of the electrode wire. Compared with the prior art, a metal workpiece subjected to cutting processing by the electrode wire is high in surface smoothness and good in surface quality, accordingly, cutting accuracy is high, meanwhile, the electrode wire preparing technology is simple, operability is high, the number of manufacturing steps is small, and large-scale and automatic production can be achieved easily.

Description

Technical field [0001] The invention relates to the technical field of high-precision electric spark wire cutting processing, in particular to a high-precision zinc-based alloy electrode wire and a preparation method thereof. Background technique [0002] In recent years, with the need for the processing of tiny parts-tiny gears, tiny splines and tiny connectors and other special and complex parts, high-precision EDM machining due to its unique processing method, that is, the characteristics of non-mechanical contact processing, especially It adapts to the requirements of micro-machine manufacturing, and has a high cost performance, so it has played an important role in many micro-machine production fields, and has obtained rapid development. The continuous exploration of high-precision EDM wire-cutting technology at home and abroad has made great progress in the integration and practicality of micro-machine manufacturing. [0003] There are many factors that affect EDM high-preci...

AI Technical Summary

Problems solved by technology

At present, there are many kinds of electrode wires on the market, such as: copper electrode wire, also known as high copper electrode wire, this kind of electrode wire has a single α-phase structure, the product has excellent toughness, has very good electrical conductivity, and can withstand the maximum instantaneous high temperature. The ability of pulse current and large cutting current, but the tensile strength of this kind of electrode wire is generally low, and the average tensile strength of hard wire is only about 400-500MPa, which is only suitable for special processing of special machine tools; brass electrode wire is currently the The most common electrode wire on the market has a dual-phase crystal structure composed of α and β. This electrode wire can achieve different tensile strengths through a series of wire drawing and heat treatment processes to meet different equipment and applications. Stretching The strength can reach more than 1000MPa, but there are more copper powder on the surface of this type of electrode wire, and the geometric error of the cross section is too large, which will lead to a decrease in discharge stability, seriously affect the processing accuracy and surface quality of the workpiece, and will also pollute the equipment components and increase Equipment loss; galvanized electrode wire, the core material of this electrode wire is common brass, and a layer of zinc is coated on the surface during preparation to form a shell with a significant η phase structure on the surface. The gasification effect helps to improve the flushing performance during surface cutting. The cutting surface is smoother than ordinary brass wire, but in the actual use process, this kind of electrode wire still has the phenomenon of powder falling, which hinders the further improvement of processing accuracy; coated electrode wire , the core material of this kind of electrode wire is mainly brass, copper or other materials, and the surface layer is a β-phase structure, or a γ-phase structure, or a β+γ-phase mixed phase structure. To a certain extent, the cutting accuracy and surface quality are improved, but this type of electrode wire is suitable for processing industries such as mold manufacturing, aviation, medical and other complex parts, high thickness and large parts, and the processing accuracy of some small and complex parts has not been maximized. Optimization, especially with the development and mature application of micro-machines, this type of electrode wire can no longer meet the precision requirements in this area

[0004] The reason why electrode wires with β-phase structure, γ-phase structure or β+γ-phase shell can improve cutting efficiency is that they can increase the energy of electric spark discharge, which makes the explosive force during discharge large and the erosion volume is large and fast, and more It is beneficial to corrode metal parts, so that the cutting efficiency of this wire electrode is significantly improved compared with ordinary wire electrodes. However, due to the large discharge energy and explosive force of this kind of wire electrode when cutting, the surface pits of the cut materials are also large. , so it is not conducive to improving the cutting accuracy and surface finish of the electrode wire

Although the galvanized electrode wire with significant η phase is relatively gentle during cutting and discharge, the amount of corrosion is small, and the pits on the surface of the cut material are small, which is conducive to improving the cutting accuracy, but the surface of this type of electrode wire is basically pure zinc. Zinc has a low melting point, relatively small vaporization enthalpy, less heat is taken away by rapid vaporization, and the effective flushing effect is poor. If the produced metal particles are not removed in time, it is easy to block the gap and cause defects. Therefore, when cutting A large amount of working fluid needs to be injected for secondary flushing, so as to avoid disconnection caused by heat accumulation, but if the flushing is not good or the working fluid is unstable, it will affect the machining accuracy, and the requirements for the flushing system of the machine tool will also be higher

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