A method for machining fine electrolytic wire cutting with large intermittent vibration of wire electrode workpiece

Abstract

The invention discloses a fine electrolytic wire cutting processing method for a wire electrode workpiece with large intermittent vibration, comprising the steps of simultaneously performing large intermittent vibration and differential motion on the wire electrode and the workpiece, wherein the large intermittent vibration is an alternating reciprocating motion of the wire electrode and the workpiece in a direction perpendicular to the processing direction, and the amplitude of the large intermittent vibration is greater than the thickness of the workpiece; the differential motion is a differential motion of the wire electrode and the workpiece in the same direction in the processing direction, and the wire electrode is continuously fed relative to the workpiece along a processing path; the invention changes the movement speed, processing position and movement direction between the wire electrode and the workpiece under the composite motion of simultaneously performing large intermittent vibration and differential motion on the wire electrode and the workpiece, so that the electrolyte in the processing gap between the wire electrode and the workpiece can flow and be updated rapidly, and the insoluble products can be rapidly discharged through repeated flushing, thereby significantly improving the processing stability, processing quality and processing efficiency.

Description

Technical Field

[0001] The invention relates to the technical field of micro-electrolytic wire cutting processing, and in particular to a micro-electrolytic wire cutting processing method for a wire electrode workpiece with large intermittent vibration. Background Art

[0002] Micro-electrolytic wire cutting processing technology is a micro-electrolytic processing method that uses micro-metal wire as the tool electrode. Through digital control of the motion trajectory of the metal wire electrode / workpiece, it can not only process structures with micro-slits, micro-grooves, etc., but also realize the preparation of microstructures / parts with complex 2D and quasi-3D shapes and large aspect ratios. This technology not only has the advantages of traditional micro-electrolytic processing, but also eliminates the process of preparing complex cathode tools and shortens the preliminary preparation time for processing.

[0003] The kerf of micro-electrolytic wire cutting is too narrow, and the electrolyte is difficult to enter the processing gap and cannot be updated in time, which reduces the electrolytic reaction speed. At the same time, the electrolytic products are difficult to discharge from the processing gap. Accumulation in the kerf will cause the composition and conductivity of the electrolyte to change, affecting the stability of electrolytic processing, and even causing a short circuit and terminating the processing. Especially for the cutting of thick workpieces, as the thickness of the workpiece increases, the deeper and narrower the kerf, the more difficult it is to remove the electrolytic products and the more difficult it is to update the electrolyte.

[0004] Patent publication number CN108788352B discloses a wire electrode workpiece different speed compound motion micro-electrolytic wire cutting processing method, the wire electrode and the workpiece perform different speed relative cutting motion in the processing direction, and the static electrolyte flows in the opposite direction and quickly flushes the product in the gap; the wire electrode and the workpiece perform alternating reciprocating motion perpendicular to the processing direction to assist mass transfer in the gap; the composite motion in different directions is used to realize the position change of the processing area, drive the electrolyte in the processing gap to quickly update and flow, and perform differential motion micro-electrolytic wire cutting processing under efficient mass transfer conditions;

[0005] However, the alternating reciprocating distance and frequency of the wire electrode and the workpiece are important factors affecting the mass transfer efficiency of the reciprocating motion. If the alternating reciprocating distance of the wire electrode and the workpiece is less than the thickness of the workpiece, there is an overlapping area in the reciprocating direction, and the insoluble electrolytic products may remain in the processing gap and are difficult to be "eliminated" by the workpiece. If the wire electrode and the workpiece "continuously" alternate reciprocate (i.e., continuously vibrate), the insoluble products in the processing gap will not have time to be completely discharged before the movement reverses, and the discharge efficiency of the insoluble products is low. In addition, if the reciprocating frequency is too high, it will cause a large range of disturbances in the electrolyte in the processing area, which can easily cause deformation of the wire electrode. The insoluble products in the processing gap cannot be completely discharged, and the discharge efficiency is low, which affects the electrolyte flow renewal speed in the processing gap, the mass transfer efficiency and material removal rate are low, the processing stability is poor, and the processing quality and processing efficiency are low. Summary of the invention

[0006] The technical problem to be solved by the present invention is to overcome the existing defects and provide a method for fine electrolytic wire cutting processing with large intermittent vibration of a wire electrode workpiece. By making the distance between the wire electrode and the workpiece large intermittent vibration greater than the thickness of the workpiece, the insoluble products can be effectively prevented from re-entering the processing gap and completely leaving the area affected by the insoluble products, thereby improving the processing conditions; by the differential movement of the wire electrode and the workpiece, the electrolyte is converted from a static state to a flowing state, thereby accelerating the diffusion and migration rate of metal ions on the processing surface, inhibiting the concentration polarization phenomenon, accelerating the discharge of products, and improving the conductivity distribution of the electrolyte in the processing gap; by changing the movement speed, processing position, and movement direction between the wire electrode and the workpiece, the speed of electrolyte renewal in the processing gap is increased, the complete discharge of insoluble products is guaranteed, the mass transfer efficiency is enhanced, the material removal rate is accelerated, and the processing stability, processing quality, and processing efficiency are significantly improved, which can effectively solve the problems in the background technology.

[0007] To achieve the above-mentioned purpose, the present invention provides the following technical solutions: a wire electrode workpiece large intermittent vibration fine electrolytic wire cutting processing method, comprising: the wire electrode and the workpiece are subjected to large intermittent vibration and differential motion at the same time, the large intermittent vibration is that the wire electrode and the workpiece are subjected to alternating reciprocating motion perpendicular to the processing direction, and the amplitude of the large intermittent vibration is greater than the thickness of the workpiece; during the large intermittent vibration, the relative position of the wire electrode and the workpiece reaches the upper limit position or the lower limit position, and then stops for a period of time and vibrates in the opposite direction again, and the movement reversal of the wire electrode and the workpiece during the large intermittent vibration is used to generate a relative speed between the electrolyte in the processing area and the processing surface of the workpiece, so that the electrolyte fully flushes the insoluble products in the processing gap; the differential motion is that the wire electrode and the workpiece move differentially in the same direction in the processing direction, and the wire electrode is continuously fed relative to the workpiece along the processing path; under the composite motion of the wire electrode and the workpiece being subjected to large intermittent vibration and differential motion at the same time, the electrolyte in the processing gap between the wire electrode and the workpiece is rapidly flowed and renewed, and the insoluble products are rapidly discharged through repeated flushing.

[0008] Furthermore, in each cycle of the large-scale intermittent vibration, the vibration stop time is greater than the vibration time.

[0009] Furthermore, the large-scale intermittent vibration is performed in a manner that the workpiece is stationary in a direction perpendicular to the machining direction, and the wire electrode intermittently reciprocates in a direction perpendicular to the machining direction.

[0010] Furthermore, the large-scale intermittent vibration is performed in a manner that the wire electrode is stationary in a direction perpendicular to the machining direction, and the workpiece intermittently reciprocates in a direction perpendicular to the machining direction.

[0011] Furthermore, the large-scale intermittent vibration is in the form of the wire electrode and the workpiece intermittently reciprocating in a direction perpendicular to the machining direction at the same time, and the reciprocating directions of the wire electrode and the workpiece are opposite.

[0012] Furthermore, in the differential motion, the wire electrode performs a relative feeding motion toward the workpiece, the motion speed V1 of the wire electrode is greater than the motion speed V2 of the workpiece, and the speed difference between the wire electrode and the workpiece is the feeding speed of the wire electrode.

[0013] Furthermore, in the differential motion, the workpiece makes a relative feeding motion toward the wire electrode, the motion speed V3 of the wire electrode is less than the motion speed V4 of the workpiece, and the speed difference between the wire electrode and the workpiece is the feeding speed of the workpiece.

[0014] Compared with the prior art, the present invention has the following beneficial effects:

[0015] 1. The wire electrode workpiece large intermittent vibration micro-electrolytic wire cutting processing method exemplified in the present invention is compared with the existing axial small-amplitude high-frequency vibration, whose vibration may re-absorb the insoluble products that have just been detached into the processing gap. In this method, the distance between the wire electrode and the workpiece with large intermittent vibration is greater than the thickness of the workpiece, which can effectively prevent the insoluble products from re-entering the processing gap. In the process of repeated flushing of the products in the processing gap, even if the insoluble products adhere to the processing surface, they can be completely separated from the area affected by the insoluble products, thereby improving the processing conditions.

[0016] 2. The wire electrode workpiece large intermittent vibration micro-electrolytic wire cutting processing method exemplified in the present invention has little effect on the flow of electrolyte compared to the existing wire electrode circular wire walking or axial vibration, resulting in the insoluble product cannot be discharged in time. The method utilizes the differential motion of the wire electrode and the workpiece to convert the electrolyte from a static state to a flowing state, thereby accelerating the diffusion and migration rate of metal ions on the processing surface, inhibiting concentration polarization, accelerating the discharge of products, and improving the conductivity distribution of the electrolyte in the processing gap.

[0017] 3. The wire electrode workpiece large intermittent vibration micro-electrolytic wire cutting processing method of the example of the present invention utilizes the large intermittent vibration of the wire electrode and the workpiece to increase the renewal rate of the electrolyte in the processing gap by changing the movement speed, processing position and movement direction, thereby ensuring the complete discharge of insoluble products, enhancing the mass transfer efficiency, accelerating the material removal rate, and significantly improving the processing stability, processing quality and processing efficiency.

[0018] 4. When the wire electrode and the workpiece vibrate greatly during the large-scale intermittent vibration of the present invention, the large-scale vibration switching stops for a period of time, and the insoluble products in the processing gap are completely flushed to the top or bottom of the workpiece by the inertia of the electrolyte flowing in the processing area perpendicular to the processing direction, and the insoluble products retained outside the processing gap are completely flushed out of the processing area by the electrolyte flowing in the differential motion of the wire electrode and the workpiece; the wire electrode and the workpiece are completely separated from the area affected by the insoluble products, the conductivity distribution of the electrolyte in the processing gap is further improved, and the efficiency and cutting quality of the fine electrolytic wire cutting are improved.

[0019] 5. In each cycle of the large-scale intermittent vibration of the present invention, the vibration stop time is greater than the vibration time, which can prevent the electrolyte in the processing area from being disturbed in a large range due to the high frequency of the large-scale vibration and causing deformation of the wire electrode, thereby improving the processing stability. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] Figure 1 It is a schematic diagram of the structure of the present invention;

[0021] Figure 2 for Figure 1 Sectional view;

[0022] Figure 3 It is a schematic diagram of the electrolyte flow field distribution and mass transfer when the workpiece static line electrode vibrates according to the present invention;

[0023] Figure 4 It is a schematic diagram of a method for fine electrolytic wire cutting with large intermittent vibration of a wire electrode workpiece according to a first embodiment of the present invention;

[0024] Figure 5 It is a schematic diagram of a method for fine electrolytic wire cutting with large intermittent vibration of a wire electrode workpiece according to a second embodiment of the present invention;

[0025] Figure 6 It is a schematic diagram of the electrolyte flow field distribution and mass transfer when the wire electrode is stationary and the workpiece is vibrating;

[0026] Figure 7 It is a schematic diagram of a method for machining a fine electrolytic wire cutting with large intermittent vibration of a wire electrode workpiece according to a third embodiment of the present invention;

[0027] Figure 8 It is a schematic diagram of a method for machining a fine electrolytic wire cutting with large intermittent vibration of a wire electrode workpiece according to a fourth embodiment of the present invention;

[0028] Fig. 9 It is a schematic diagram of the electrolyte flow field distribution and mass transfer when the wire electrode and the workpiece vibrate in opposite directions simultaneously in the present invention;

[0029] Fig.10 It is a schematic diagram of a fifth embodiment of the present invention's method for fine electrolytic wire cutting with large intermittent vibration of a wire electrode workpiece;

[0030] Fig.11 It is a schematic diagram of a sixth embodiment of a method for fine electrolytic wire cutting with large intermittent vibration of a wire electrode workpiece according to the present invention.

[0031] In the figure: 1. wire electrode; 2. workpiece. DETAILED DESCRIPTION

[0032] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention. Embodiment 1

[0033] See also Figure 1-4 , the present invention provides a technical solution: a wire electrode workpiece large intermittent vibration micro electrolytic wire cutting processing method, comprising the wire electrode 1 and the workpiece 2 simultaneously performing large intermittent vibration and differential motion;

[0034] The large-scale intermittent vibration is that the workpiece 2 is stationary at right angles to the machining direction, and the wire electrode 1 intermittently reciprocates at right angles to the machining direction. After the wire electrode 1 moves to the upper limit position or the lower limit position, it stops for a period of time and then moves in the opposite direction again. In each cycle of the large-scale intermittent vibration of the wire electrode 1, its vibration stop time is greater than the vibration time. The movement reversal of the wire electrode 1 during the large-scale intermittent vibration is used to generate a relative speed between the electrolyte in the machining area and the machining surface of the workpiece 2, so that the electrolyte fully flushes the insoluble products in the machining gap. The amplitude of the large-scale intermittent vibration of the wire electrode 1 is greater than the thickness of the workpiece 2.

[0035] The differential motion is that the wire electrode 1 and the workpiece 2 move differentially in the same direction in the machining direction, and in the differential motion, the wire electrode 1 makes a relative feeding motion toward the workpiece 2, the movement speed V1 of the wire electrode 1 is greater than the movement speed V2 of the workpiece 2, the wire electrode 1 continuously feeds along the machining path relative to the workpiece 2, and the speed difference between the wire electrode 1 and the workpiece 2 is the feeding speed of the wire electrode 1;

[0036] The wire electrode workpiece large intermittent vibration micro-electrolytic wire cutting processing method disclosed in the present embodiment is achieved by the intermittent reciprocating movement of the wire electrode 1 in a direction perpendicular to the processing direction. When the wire electrode 1 vibrates with large intervals, it "drags" the electrolyte in the processing area to reciprocate in the direction perpendicular to the processing direction, so that the electrolyte flushes the insoluble products out of the processing gap, and the electrolyte in the processing gap is flowed and renewed, and the insoluble products in the processing gap are repeatedly flushed and quickly discharged; the amplitude of the large intermittent vibration of the wire electrode 1 is greater than the thickness of the workpiece 2, that is, when the wire electrode 1 moves to the upper limit position or the lower limit position, the insoluble products are completely "dragged" out of the processing gap, and the differential motion of the wire electrode 1 and the workpiece 2 is coordinated to make the electrolyte in the processing area change from a static state to a flowing state, effectively preventing the insoluble products from entering the processing gap again.

[0037] After the wire electrode 1 moves to the upper limit position or the lower limit position, it stops for a period of time, that is, the wire electrode 1 stops for a period of time when the movement direction of the large intermittent vibration is reversed, and the insoluble products in the processing gap are completely flushed to the top or bottom of the workpiece 2 by utilizing the inertia of the electrolyte flowing in the processing area perpendicular to the processing direction, and the insoluble products retained outside the processing gap are completely flushed out of the processing area by utilizing the electrolyte flowing in the differential motion of the wire electrode 1 and the workpiece 2, thereby accelerating the diffusion and migration rate of metal ions on the processing surface, suppressing the concentration polarization phenomenon, and accelerating the discharge of products; the wire electrode 1 and the workpiece 2 are completely separated from the area affected by the insoluble products, further improving the conductivity distribution of the electrolyte in the processing gap, and improving the efficiency and cutting quality of the micro-electrolytic wire cutting.

[0038] The vibration stop time of the wire electrode 1 in each cycle of large-scale intermittent vibration is greater than the vibration time, which can not only allow the electrolyte flowing in the processing area to wash away the insoluble products discharged outside the processing gap, but also prevent the electrolyte in the processing area from being disturbed in a large range due to the high frequency of large-scale vibration, causing deformation of the wire electrode 1, thereby affecting the processing stability. Embodiment 2

[0039] See also Figure 1-3 and Figure 5 , this embodiment is relative to the first embodiment: in the differential motion, the workpiece 2 makes a relative feeding motion toward the wire electrode 1, the motion speed V3 of the wire electrode 1 is less than the motion speed V4 of the workpiece 2, the wire electrode 1 continuously feeds along the machining path relative to the workpiece 2, and the speed difference between the wire electrode 1 and the workpiece 2 is the feed speed of the workpiece 2;

[0040] Compared with the first embodiment, this embodiment provides another differential motion mode of the wire electrode 1 and the workpiece 2 . Embodiment 3

[0041] See also Figure 1-2 and Figure 6-7 , this embodiment is relative to the first embodiment: the large-scale intermittent vibration is that the wire electrode 1 is stationary at right angles to the machining direction, and the workpiece 2 intermittently reciprocates at right angles to the machining direction. After the workpiece 2 moves to the upper limit position or the lower limit position, it stops for a period of time and then moves in the opposite direction again. The vibration stop time of the workpiece 2 in each cycle of the large-scale intermittent vibration is greater than the vibration time. The movement reversal of the workpiece 2 during the large-scale intermittent vibration is used to generate a relative speed between the electrolyte in the machining area and the machining surface of the workpiece 2, so that the electrolyte can fully flush the insoluble products in the machining gap; the amplitude of the large-scale intermittent vibration of the workpiece 2 is greater than the thickness of the workpiece 2, that is, when the workpiece 2 moves to the upper limit position or the lower limit position, it completely leaves its original machining gap position, and cooperates with the differential motion of the wire electrode 1 and the workpiece 2 to make the electrolyte in the machining area change from a stationary state to a flowing state, effectively preventing the insoluble products from entering the machining gap again;

[0042] Compared with the first embodiment, the present embodiment provides another method of performing large-scale intermittent vibration between the wire electrode 1 and the workpiece 2. The large-scale intermittent vibration of the workpiece 2 is utilized to actively separate the to-be-processed area of ​​the workpiece 2 from the processing gap affected by the insoluble products, and the reciprocating movement of the workpiece 2 drives the electrolyte in the processing area to reciprocate in a direction perpendicular to the processing direction, so that the electrolyte flushes the insoluble products out of the processing gap. Embodiment 4

[0043] See also Figure 1-2 , Figure 6 and Figure 8, this embodiment is relative to the third embodiment: in the differential motion, the workpiece 2 makes a relative feeding motion toward the wire electrode 1, the motion speed V3 of the wire electrode 1 is less than the motion speed V4 of the workpiece 2, the wire electrode 1 continuously feeds along the machining path relative to the workpiece 2, and the speed difference between the wire electrode 1 and the workpiece 2 is the feed speed of the workpiece 2;

[0044] Compared with the third embodiment, this embodiment provides another differential motion mode of the wire electrode 1 and the workpiece 2 . Embodiment 5

[0045] See also Figure 1-2 and Figure 9-10 , this embodiment is relative to the first embodiment: the large-scale intermittent vibration is that the wire electrode 1 and the workpiece 2 simultaneously intermittently reciprocate in a direction perpendicular to the processing direction, and the reciprocating directions of the wire electrode 1 and the workpiece 2 are opposite. After the wire electrode 1 and the workpiece 2 move to the upper limit position or the lower limit position, they stop for a period of time and then move in the opposite direction again. The vibration stop time of the wire electrode 1 and the workpiece 2 in each cycle of the large-scale intermittent vibration is greater than the vibration time. The movement reversal of the wire electrode 1 and the workpiece 2 during the large-scale intermittent vibration is used to generate a relative speed between the electrolyte in the processing area and the processing surface of the workpiece 2, so that the electrolyte fully flushes the insoluble products in the processing gap; the amplitude of the large-scale intermittent vibration of the wire electrode 1 and the workpiece 2 is greater than the thickness of the workpiece 2; the insoluble products in the processing gap are completely discharged before the movement reversal occurs, effectively preventing the insoluble products from entering the processing gap again;

[0046] Compared with the first embodiment, the present embodiment provides another method of large-scale intermittent vibration of the wire electrode 1 and the workpiece 2. By having the wire electrode 1 and the workpiece 2 intermittently reciprocate in opposite directions perpendicular to the processing direction at the same time, the discharge efficiency of the insoluble products in the processing gap is further improved, and the rapid flow and renewal of the electrolyte in the processing gap is further accelerated, so that the insoluble products in the processing gap are quickly discharged through repeated flushing. Embodiment 6

[0047] See also Figure 1-2 , Fig. 9 and Fig.11 , this embodiment is relative to the fifth embodiment: in the differential motion, the workpiece 2 makes a relative feeding motion toward the wire electrode 1, the motion speed V3 of the wire electrode 1 is less than the motion speed V4 of the workpiece 2, the wire electrode 1 continuously feeds along the machining path relative to the workpiece 2, and the speed difference between the wire electrode 1 and the workpiece 2 is the feed speed of the workpiece 2;

[0048] Compared with the fifth embodiment, this embodiment provides another differential motion mode of the wire electrode 1 and the workpiece 2 .

[0049] Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and spirit of the present invention, and that the scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A method for machining fine electrolytic wire cutting with large intermittent vibration of a wire electrode workpiece, characterized in that: The invention comprises a wire electrode (1) and a workpiece (2) performing large-scale intermittent vibration and differential motion simultaneously, wherein the large-scale intermittent vibration is an alternating reciprocating motion of the wire electrode (1) and the workpiece (2) in a direction perpendicular to the machining direction, and the amplitude of the large-scale intermittent vibration is greater than the thickness of the workpiece (2); during the large-scale intermittent vibration, the relative position of the wire electrode (1) and the workpiece (2) reaches an upper limit position or a lower limit position, then stops for a period of time and then vibrates in the opposite direction; in each cycle of the large-scale intermittent vibration, the vibration stop time is greater than the vibration time; and the movement of the wire electrode (1) and the workpiece (2) during the large-scale intermittent vibration is used to change the vibration. The relative speed between the electrolyte in the processing area and the processing surface of the workpiece (2) is generated, so that the electrolyte fully flushes the insoluble products in the processing gap; the differential motion is that the wire electrode (1) and the workpiece (2) move differentially in the same direction in the processing direction, and the wire electrode (1) is continuously fed along the processing path relative to the workpiece (2); the wire electrode (1) and the workpiece (2) simultaneously perform a composite motion of large-scale intermittent vibration and differential motion, so that the electrolyte in the processing gap between the wire electrode (1) and the workpiece (2) is rapidly flowed and renewed, and the insoluble products are rapidly discharged through repeated flushing.

2. The method for machining a wire electrode workpiece with large intermittent vibration of a fine electrolytic wire cutting according to claim 1, characterized in that: The large-scale intermittent vibration is performed in a manner that the workpiece (2) is stationary in a direction perpendicular to the machining direction, and the wire electrode (1) intermittently reciprocates in a direction perpendicular to the machining direction.

3. The method for machining a wire electrode workpiece with large intermittent vibration of a fine electrolytic wire cutting according to claim 1, characterized in that: The large-scale intermittent vibration is in the form of the wire electrode (1) being stationary in a direction perpendicular to the machining direction, and the workpiece (2) being reciprocating intermittently in a direction perpendicular to the machining direction.

4. The method for machining a wire electrode workpiece with large intermittent vibration of a fine electrolytic wire cutting according to claim 1, characterized in that: The large-scale intermittent vibration is performed in such a way that the wire electrode (1) and the workpiece (2) simultaneously and intermittently reciprocate in a direction perpendicular to the machining direction, and the reciprocating directions of the wire electrode (1) and the workpiece (2) are opposite.

5. The method for machining a wire electrode workpiece with large intermittent vibration of a fine electrolytic wire cutting according to claim 1, characterized in that: In the differential motion, the wire electrode (1) performs a relative feeding motion toward the workpiece (2), the motion speed V1 of the wire electrode (1) is greater than the motion speed V2 of the workpiece (2), and the speed difference between the wire electrode (1) and the workpiece (2) is the feeding speed of the wire electrode (1).

6. The method for machining a wire electrode workpiece with large intermittent vibration of a fine electrolytic wire cutting according to claim 1, characterized in that: In the differential motion, the workpiece (2) performs a relative feed motion toward the wire electrode (1), the motion speed V3 of the wire electrode (1) is less than the motion speed V4 of the workpiece (2), and the speed difference between the wire electrode (1) and the workpiece (2) is the feed speed of the workpiece (2).

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