Pulse electric conduction and mechanical cutting combined machining method of metal material

Abstract

The application discloses a kind of metal material's pulse conduction and mechanical cutting composite processing method, when cutting metal by using cutter, high-frequency pulse power is passed in cutting area (wedge area), due to electromagnetic heat effect, the temperature of material around wedge cutting zone tip is rapidly increased, the material is softened, the hardness of cutting area material is reduced, so that mechanical cutting becomes easy.The specific steps are as follows: install pulse power supply on machine tool, and connect with both ends of workpiece to form current loop; then adjust pulse power supply parameters, and cut metal workpiece installed on machine tool workbench.The application of a kind of metal material's conduction and mechanical cutting composite processing method has high production efficiency, improves processing precision and quality, and is suitable for cutting processing of any type cutter, and is an effective method for conventional processing, precision and micro machining of ordinary metal materials and difficult-to-machine materials used in aerospace and other industrial products.

Description

Technical Field

[0001] This invention relates to a processing method that combines pulse conductivity and mechanical cutting of metallic materials. Background Technology

[0002] With the development of materials science, especially in the aerospace, nuclear energy, and weaponry industries, engineering structural materials with special properties are widely used, leading to an increasing number of difficult-to-machine metallic materials, such as stainless steel, titanium alloys, and high-temperature alloys. Traditional machining methods are slow, costly, and produce low-quality results. Meeting the requirements of machinability, precision, and surface quality for these new materials presents new challenges to existing processing technologies. Conductive heating machining is a composite manufacturing technology that has gradually emerged in this context.

[0003] Currently, conductive heating-assisted cutting technology is an electric contact heating cutting process. In this process, a low voltage and high current are passed through a circuit consisting of the tool and the workpiece to generate Joule heating in the material. This heats up the cutting layer area, reduces its hardness, and improves processing efficiency. It has advantages that traditional single processing technologies do not have, and it is one of the development directions of manufacturing technology in the field of efficient processing of the aforementioned difficult-to-machine materials.

[0004] However, this conductive heating cutting technology currently has significant drawbacks. First, it is unsuitable for cutting non-metallic materials with cutting tools (such as ceramic tools, diamond tools, and cubic boron nitride tools), limiting the range of tools that can be used and consequently greatly restricting the range of materials that can be processed. Second, it cannot perform intermittent cutting because the strong electric arc generated during intermittent cutting can burn the tool, affecting its lifespan, surface finish, and reducing machining safety. Finally, it cannot be used in high-speed cutting processes, which also significantly impacts production efficiency. These limitations severely restrict the application of this conductive heating cutting technology, which uses a circuit formed by the tool and workpiece. Summary of the Invention

[0005] The purpose of this invention is to address the shortcomings of existing conductive heating cutting technologies by providing a composite machining method for metallic materials that combines pulsed conductive heating with mechanical cutting. This method utilizes the electromagnetic thermal effect to continuously pulse discharge and heat the wedge-shaped cutting area of ​​the workpiece with a high-frequency pulsed current, while simultaneously performing traditional mechanical cutting, thus forming a novel composite cutting machining method.

[0006] This invention employs a high-frequency pulsed power supply. A dedicated anode connector for pulsed power supply machining is installed on one end of the metal material, connecting the workpiece to the positive terminal of the pulsed power supply. A dedicated cathode connector for pulsed power supply machining is installed on the cutting tool, ensuring contact between the cathode and the processed chip, forming a current loop. The current flows from the anode to the workpiece, from the workpiece to the chip, from the chip to the cathode connector, and finally back to the cathode. Simultaneously, the cutting tool must be insulated, or an insulated non-metallic tool should be used, meaning the current does not pass through the tool. When the sharp tool tip (possibly with a large rake and clearance angle) cuts into the workpiece, the chip root forms a wedge shape with the machined surface. The high-frequency pulsed current passing through the wedge-shaped cutting tip region (approximately a crack) causes current to flow around and concentrate in the wedge-shaped cutting tip region. Figure 1 As shown in the diagram, this generates intense Joule heating, converting electrical energy into heat energy. This causes the temperature of the material around the tip of the wedge-shaped cutting zone to rise rapidly, to a level sufficient to soften or even melt the material. This significantly reduces the hardness of the material in the cutting area (especially the shear deformation zone), making machining much easier and thus improving cutting efficiency and machining quality.

[0007] The specific steps involve installing a high-frequency pulse power supply on a machine tool to process the anode-specific connector, adjusting the appropriate pulse power supply parameters, and using the pulse power supply to perform conductive cutting on the metal workpiece placed on the anode worktable. This can efficiently and quickly remove machining allowances, while ensuring machining quality and extending tool life.

[0008] To achieve the above objectives, the present invention adopts the following technical solution: a processing method for metallic materials combining pulse conductivity and mechanical cutting, comprising the following steps:

[0009] (1) Install a pulse power supply device:

[0010] This processing method uses an adjustable pulse power supply, and the pulse power supply device should be installed in a suitable position.

[0011] (2) Install the special connector for pulse power supply machining anode:

[0012] Install the pulse power supply anode special connector on the machine tool, and connect the pulse power supply anode cable to the pulse power supply anode special connector.

[0013] (3) Install the pulse power supply for machining the cathode special connector:

[0014] Install the pulse power supply cathode connector on the cutting tool and connect the pulse power supply cathode cable. Make the power supply cathode contact with the chip formed during machining to form a current loop. That is, the current flows from the pulse power supply anode connector to the workpiece, from the workpiece to the chip, from the chip to the pulse power supply cathode connector, and finally back to the pulse power supply cathode. At the same time, the cutting tool should be insulated or an insulated non-metallic tool should be used to prevent the current from passing through the tool.

[0015] (4) Install the workpiece:

[0016] Use tooling to mount the metal workpiece onto the pulse power supply anode worktable;

[0017] (5) Machining by cutting:

[0018] Start the cutting machine tool, and the cutting tool will cut the workpiece;

[0019] (6) Turn on the pulse power supply: Set the processing parameters in the pulse power supply device, turn on the pulse power supply to enter the discharge heating stage of the wedge cutting processing area of ​​the workpiece. The pulse power supply is adjustable. Input a 220V, 50Hz power supply, and the output current can be selected between 0 and 3000A according to the processing conditions. When the pulse power supply continuously conducts conductive heating on the wedge cutting processing area, an electromagnetic thermal effect will occur, generating a large amount of heat and softening the metal material in the wedge cutting processing area.

[0020] Furthermore, the connection point between the pulse power processing anode special connector and the machine tool in step (2) should be insulated and connected to the pulse power processing anode cable via a quick-connect plug.

[0021] Furthermore, the cutting tool in step (3) needs to be insulated. An insulating layer is installed between the pulse power processing cathode connector and the cutting tool mounting position, and it is connected to the pulse power processing cathode cable through a quick connector.

[0022] Furthermore, the cutting tools mentioned in step (5) include high-speed steel tools, cemented carbide tools, and diamond tools.

[0023] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0024] This invention is a machining method that combines pulsed power supply to conduct electricity to a metal workpiece with mechanical cutting. It efficiently removes machining allowances and is suitable for precision and micro-cutting of metal materials. It also effectively meets the machining requirements of difficult-to-machine materials used in defense and military products. Compared to traditional conductive heating mechanical cutting, this invention offers advantages such as increased cutting efficiency, reduced processing costs, and guaranteed processing quality. It also features safe, reliable, and convenient operation of the machining device, less tool wear, a wide range of applicable tools, and a broad range of machined metal materials. Attached Figure Description

[0025] The accompanying drawings are provided to further illustrate the invention and form part of the specification. They are used together with the embodiments of the invention to explain the invention, but do not constitute a limitation thereof.

[0026] Figure 1 This is a schematic diagram of the electromagnetic thermal cutting process of the present invention;

[0027] Figure 2 This is a front view of the working state of the electromagnetic thermal cutting process of the present invention;

[0028] Figure 3 This is a partial schematic diagram of the electromagnetic thermal cutting process of the present invention.

[0029] Explanation of reference numerals in the attached drawings: 1. Pulse power supply device; 2. Pulse power supply anode-specific connector; 3. Machine tool fixture; 4. Metal workpiece; 5. Chip layer; 6. Cutting tool; 7. Pulse power supply cathode-specific connector; 8. Cable. Detailed Implementation

[0030] like Figures 1-3 As shown:

[0031] (1) Install a pulse power supply device:

[0032] This processing method uses an adjustable pulse power supply. The pulse power supply device 1 should be installed in a suitable position.

[0033] (2) Install the special connector for pulse power supply machining anode:

[0034] Install the pulse power anode special connector 2 on the machine tool, and connect the pulse power anode cable 8 to the pulse power anode special connector 2.

[0035] (3) Install the pulse power supply for machining the cathode special connector:

[0036] Install the pulse power processing cathode connector 7 on the cutting tool 6 and connect the pulse power processing cathode cable 8. Make the pulse power processing cathode contact with the processed chip 5 to form a current loop. That is, the current flows from the pulse power processing anode connector 2 to the workpiece 4, from the workpiece 4 to the chip 5, then from the chip 5 to the pulse power processing cathode connector 7, and finally back to the pulse power cathode current loop. At the same time, the cutting tool 6 should be insulated or an insulated non-metallic tool should be used to prevent the current from passing through the cutting tool 6.

[0037] (4) Install the workpiece:

[0038] Use tooling to mount the metal workpiece 4 onto the pulse power supply anode worktable;

[0039] (5) Machining by cutting:

[0040] Start the cutting machine tool, and the cutting tool 6 performs cutting on the workpiece 4;

[0041] (6) Turn on the pulse power supply:

[0042] Set the processing parameters in the pulse power supply device 1, turn on the pulse power supply to enter the discharge heating stage of the wedge cutting processing area of ​​workpiece 4. The pulse power supply is adjustable. Input a 220V, 50Hz power supply, and the output current can be selected between 0 and 3000A according to the processing conditions. When the pulse power supply continuously conducts conductive heating on the wedge cutting processing area, an electromagnetic thermal effect will occur, generating a large amount of heat and softening the metal material in the wedge cutting processing area.

[0043] In step (2), the connection point between the pulse power processing anode special connector 2 and the machine tool must be insulated and connected to the pulse power processing anode cable 8 via a quick-connect plug.

[0044] In step (3), the cutting tool 6 is to be insulated. An insulating layer is installed between the pulse power processing cathode connector 7 and the installation position of the cutting tool 6, and it is connected to the pulse power processing cathode cable 8 through a quick connector.

[0045] The cutting tool 6 mentioned in step (5) includes high-speed steel tools, cemented carbide tools, and diamond tools.

[0046] The embodiments described above are merely preferred embodiments of the present invention and are not intended to limit the scope of the present invention. Various modifications and improvements made by those skilled in the art to the technical solutions of the present invention without departing from the spirit of the present invention should fall within the protection scope defined by the claims of the present invention.

Claims

1. A machining method for metallic materials combining pulsed conductivity and mechanical cutting, characterized in that, Includes the following steps: (1) Install a pulse power supply device: This processing method uses an adjustable pulse power supply, and the pulse power supply device should be installed in a suitable position. (2) Install the special connector for pulse power supply machining anode: Install the pulse power supply anode special connector on the machine tool, and connect the pulse power supply anode cable to the pulse power supply anode special connector. (3) Install the pulse power supply for machining the cathode special connector: Install the pulse power supply cathode connector on the cutting tool and connect the pulse power supply cathode cable. Make the power supply cathode contact with the chip formed during machining to form a current loop. That is, the current flows from the pulse power supply anode connector to the workpiece, from the workpiece to the chip, from the chip to the pulse power supply cathode connector, and finally back to the pulse power supply cathode current loop. At the same time, the cutting tool should be insulated or an insulated non-metallic tool should be used to prevent the current from passing through the tool. (4) Install the workpiece: Use tooling to mount the metal workpiece onto the pulse power supply anode worktable; (5) Machining by cutting: Start the cutting machine tool, and the cutting tool will cut the workpiece; (6) Turn on the pulse power supply: Set the processing parameters in the pulse power supply device, turn on the pulse power supply to enter the discharge heating stage of the wedge cutting processing area of ​​the workpiece. The pulse power supply is adjustable. Input a 220V, 50Hz power supply, and the output current can be selected between 0 and 3000A according to the processing conditions. When the pulse power supply continuously conducts conductive heating on the wedge cutting processing area, an electromagnetic thermal effect will occur, generating a large amount of heat and softening the metal material in the wedge cutting processing area.

2. The processing method for a composite pulse conductivity and mechanical cutting of metallic materials according to claim 1, characterized in that, In step (2), the connection point between the pulse power processing anode special connector and the machine tool should be insulated and connected to the pulse power processing anode cable via a quick-connect plug.

3. The processing method for a metallic material combining pulse conductivity and mechanical cutting according to claim 1, characterized in that, The cutting tool in step (3) needs to be insulated. An insulating layer is installed between the pulse power machining cathode connector and the cutting tool mounting position, and it is connected to the pulse power machining cathode cable through a quick connector.

4. The processing method for a metallic material combining pulse conductivity and mechanical cutting according to claim 1, characterized in that, The cutting tools mentioned in step (5) include high-speed steel tools, cemented carbide tools, and diamond tools.

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