Device for improving discharge machining efficiency of metal component

Abstract

The invention discloses a device for improving the electrical discharge machining efficiency of a metal component, which comprises an axial machining assembly for axially machining a workpiece; the axial machining assembly comprises an electrode body, a hook component and a connecting structure. The electrode main body comprises an electrode bar and a limiting bar; the limiting rod is vertically connected with the tail end of the electrode rod; the hook part is arranged at the tail part of the workpiece to be machined; the connecting structure is used for locking and connecting the hook component and the limiting rod, and a limiting boss is arranged on the side, close to a workpiece to be machined, of the limiting rod. The electrode bar is provided with a discharging area, and the to-be-machined area is machined through discharging. According to the invention, equipment and site occupation during batch production of similar structures can be reduced, the production efficiency is improved, and the production cost is reduced.

Description

Technical Field

[0001] The invention relates to a device for improving the efficiency of electric discharge machining of metal components, belonging to the technical field of special manufacturing processes. Background Art

[0002] The "blind cavity" structure is as follows Figure 3 As shown in the figure, this type of structure is often used in the head cover of the missile body, the tail cabin structure of the tail, and the local mounting seat, and is widely used in the missile body structure of the model. In order to ensure the technical and tactical indicators of the model, this type of component is often designed as an integral component, and contains certain mounting seats or reinforcing ribs inside.

[0003] Due to the limitation of structural dimensions and other factors, the root margin must be removed by EDM during the forming of this type of structure. In the actual production process, due to the limitations of the electrolysis process, the feed of the forming electrode needs to be adjusted at any time to control the reasonable gap between the workpiece and the electrode, so as to ensure the electrolysis efficiency. To solve this problem, it is often necessary to fix the electrode on the feed shaft of the machining equipment to realize the electrode feed, which leads to several problems:

[0004] 1. The feed speed depends entirely on experience and cannot be optimized in real time.

[0005] During EDM, the gap between the electrode and the workpiece needs to be kept as small as possible, but there should be no direct contact. Therefore, the feed speed parameter is crucial. In actual production, this parameter depends entirely on the operator's experience and cannot be optimized.

[0006] 2. The equipment time is high

[0007] The electrolytic machining process requires a long-term occupation of the machining center to provide feed, which results in a high process cost for the forming process.

[0008] 3. Not conducive to large-scale batch production

[0009] Due to the influence of the above two unfavorable factors, it is difficult for this process to overcome the problems of long cycle and high cost in mass production, which limits its application in mass production. Summary of the invention

[0010] The technical problem solved by the present invention is: to overcome the deficiencies of the prior art and to provide a device for improving the efficiency of electric discharge machining of metal components, so as to solve the problem of great difficulty and long cycle in machining such structural components.

[0011] The technical solution of the present invention is:

[0012] The present invention discloses a device for improving the efficiency of electric discharge machining of metal components, comprising: an axial machining component, used for axial machining of a workpiece; the axial machining component comprises an electrode body, a hook component and a connecting structure; the electrode body comprises an electrode rod and a limit rod; the limit rod is vertically connected to the tail end of the electrode rod; the hook component is arranged at the tail of the workpiece to be machined; the connecting structure is used for locking and connecting the hook component and the limit rod, and a limit boss is arranged on the limit rod close to the side of the workpiece to be machined; a discharge area is arranged on the electrode rod, and discharge realizes machining of the area to be machined.

[0013] Furthermore, the above device further comprises a radial processing assembly for radially processing the workpiece to be processed; the radial processing assembly comprises a radial electrode body, a slider and an elastic element; wherein the radial electrode body comprises an electrode rod and a processing head; the processing head is located at one end of the motor rod; the processing head is symmetrically provided with two grooves along the radial direction of the workpiece; the slider is a T-shaped structure; one end of the slider is located in the groove, and the other end is provided with a discharge area, which contacts the area to be processed for discharge processing; the elastic element is located between the slider and the electrode body to achieve clearance fit between the slider and the electrode body; at the same time, the elastic element achieves the fit between the workpiece to be processed and the slider;

[0014] Furthermore, in the above device, the surface of the discharge area is evenly distributed with insulators; the insulators are arranged in strip, mesh or granular form; the number of insulators in any length direction of the discharge area is not less than 2; the gap b between the insulators is not greater than 20 mm; and the thickness a of the insulator is 0.2 to 5 mm.

[0015] Furthermore, in the above device, L=Q-δ; L is the limiting distance between the limiting boss and the boundary of the workpiece, Q is the thickness to be processed, δ is the allowance to be processed, and δ=0.3~0.5mm.

[0016] Furthermore, in the above device, h>0.5C, h is the height of the electrode rod, and C is the length of the electrode rod.

[0017] Furthermore, in the above device, F1-Q1*L≥50; wherein F1 is the pre-tightening tension of the connecting mechanism in the axial direction of the component to be processed; Q1 is the elastic coefficient; and L is the limiting distance.

[0018] Furthermore, in the above device, the gap between the slider and the radial electrode body is not less than 0.3 mm.

[0019] Furthermore, in the above device, limit rods are provided on both sides of the slider; the distance between the limit rods and the workpiece to be processed is T=Q1-β; Q1 is the thickness of the area to be processed, β is the allowance to be processed, β=0.1~0.3mm.

[0020] Furthermore, in the above device, m>0.5n and m≥2cm; wherein, m is the distance between the contact point between the elastic element and the motor body and one end point of the slider in the groove when the elastic element is not compressed, and n is the contact surface length between the slider and the area to be processed.

[0021] Furthermore, in the above device, F2-Q2*T≥10, wherein F2 is the preload pressure of the elastic element in the radial direction of the component to be processed; Q2 is the elastic coefficient, and T is the limit distance.

[0022] The beneficial effects of the present invention and the prior art are:

[0023] (1) The present invention adopts a flexible design concept to achieve adaptive adjustment of the electromachining process, which largely solves the problems of low electromachining efficiency, high cost, high processing difficulty and long cycle. Through the three aspects of adaptive electrode design, electrode surface optimization and process optimization, the production efficiency is improved and the cost is reduced.

[0024] (2) The technical solution of the adaptive tooling of the present invention reduces the process complexity of electrical machining, gets rid of the dependence of the process on equipment capabilities, can significantly reduce site occupancy, and greatly eliminate the need for machine tool equipment.

[0025] (3) In the case of adaptive electrode feeding, the process method does not occupy processing equipment and only requires power supply and electrolyte. Under this process route, components can be connected in parallel and immersed in the processing electrolyte in batches to achieve batch production; it can significantly reduce the site and equipment occupation and can change single-piece processing to batch production.

[0026] (4) The present invention has relatively low control over dimensional accuracy. For products with low precision requirements, product production can be achieved directly; for products with high precision requirements, this process can be used to remove large excesses, and then combined with traditional processes to achieve the final forming accuracy. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] Figure 1 It is a schematic diagram of the structural principle of the axial processing assembly of the present invention;

[0028] Figure 2 It is a schematic diagram of the structural principle of the radial processing assembly of the present invention;

[0029] Figure 3 It is a schematic diagram of a traditional processing device. DETAILED DESCRIPTION

[0030] The present invention is further described in detail below in conjunction with the accompanying drawings and specific implementation methods.

[0031] like Figure 1As shown, the present invention discloses a device for improving the efficiency of electric discharge machining of metal components, comprising: an axial machining component, used for axial machining of a workpiece; the axial machining component comprises an electrode body, a hook component and a connecting structure; the electrode body comprises an electrode rod and a limit rod; the limit rod is vertically connected to the tail end of the electrode rod; the hook component is arranged at the tail of the workpiece to be machined; the connecting structure is used to lock and connect the hook component and the limit rod, and the limit rod is provided with a limit boss close to one side of the workpiece to be machined; the electrode rod is provided with a discharge area, and discharge realizes the processing of the area to be machined.

[0032] Preferably, if Figure 2 As shown, it also includes a radial processing component for radial processing of the workpiece to be processed; the radial processing component includes a radial electrode body, a slider and an elastic element; wherein the radial electrode body includes an electrode rod and a processing head; the processing head is located at one end of the motor rod; the processing head is symmetrically provided with two grooves along the radial direction of the workpiece; the slider is a T-shaped structure; one end of the slider is located in the groove, and the other end is provided with a discharge area, which contacts the area to be processed for discharge processing; the elastic element is located between the slider and the electrode body to achieve a clearance fit between the slider and the electrode body; at the same time, the elastic element achieves the fit between the workpiece to be processed and the slider;

[0033] Preferably, the surface of the discharge area is evenly distributed with insulators; the insulators are arranged in strip, mesh or granular form; the number of insulators in any length direction of the discharge area is not less than 2; the gap b between the insulators is not greater than 20 mm; and the thickness a of the insulator is 0.2 to 5 mm.

[0034] Preferably, L=Q-δ; L is the limiting distance between the limiting boss and the boundary of the workpiece, Q is the thickness to be processed, δ is the allowance to be processed, and δ=0.3-0.5 mm.

[0035] Preferably, h>0.5C, h is the height of the electrode rod, and C is the length of the electrode rod.

[0036] Preferably, F1-Q1*L≥50; wherein F1 is the pre-tightening tension of the connecting mechanism in the axial direction of the component to be processed; Q1 is the elastic coefficient; and L is the limiting distance.

[0037] Preferably, the gap between the slider and the radial electrode body is not less than 0.3 mm.

[0038] Preferably, limit rods are provided on both sides of the slide block; the distance between the limit rods and the workpiece to be processed is T=Q1-β; Q1 is the thickness of the area to be processed, β is the allowance to be processed, β=0.1-0.3mm.

[0039] Preferably, m>0.5n and m≥2cm; wherein, m is the distance between the contact point between the elastic element and the motor body and one end point of the slider in the groove when the elastic element is not compressed, and n is the contact surface length between the slider and the area to be processed.

[0040] Preferably, F2-Q2*T≥10, wherein F2 is the preload pressure of the elastic element in the radial direction of the component to be processed; Q2 is the elastic coefficient, and T is the limiting distance.

[0041] This embodiment provides a method for improving the efficiency of electrical discharge machining of metal components, comprising the following steps:

[0042] 1. Optimization design of automatic feeding electromachining device

[0043] Traditionally, electrical machining is fed by the machine tool spindle, and the discharge effect between the electrode and the workpiece is used to continuously remove the workpiece excess.

[0044] The present invention completes the contour design of the electrode working area according to the structural dimensions of the product area to be processed, and sets an elastic connection structure at the tail of the electrode. The form of the connection structure depends on the location of the area to be removed, as detailed below:

[0045] 1.1 When the area to be removed is in the axial direction

[0046] The overall structure of the electrode is Figure 1 As shown, its design has the following optimizations:

[0047] a. A connecting hook is provided at the tail of the electrode, and a resilient elastic structure is used to lock the two hooks to achieve the connection between the workpiece and the electrode.

[0048] b. On the surface of the electrode discharge area, a certain number of insulators are set. The insulators are set in strip, mesh or granular shape. The number of insulators follows the following principles:

[0049] 1) The insulator is evenly distributed on the discharge surface;

[0050] 2) The number of insulators in any length direction of the discharge surface shall not be less than 2 (strips / particles);

[0051] 3) The gap between insulators shall not exceed 20 mm;

[0052] 4) The thickness of the insulator is 0.2 to 5 mm.

[0053] c. A limiting structure is set on the electrode body to lock the maximum allowable removal amount of the product. The distance L between the limiting structure and the workpiece and the amount to be removed have the following relationship:

[0054] L = amount to be removed - (0.3~0.5) mm

[0055] d. Increase the height h of the discharge part of the electrode. The direction of traditional electrical machining is controlled by the machine tool spindle, and the height h of the electrode is usually small. In this solution, in order to enhance the guidance of the electrical machining direction, h needs to be greatly increased, so that the number of insulators that can be set is greater than or equal to 4, or h>0.5C.

[0056] 1.2 When the area to be removed is in the radial direction

[0057] The overall structure of the electrode is Figure 2 As shown, there are the following targeted optimizations in structure:

[0058] a. A radially sliding slider is provided at the head of the electrode, and there is a clearance fit between the slider and the electrode body, and the clearance is not less than 0.3mm. The workpiece and the electrode slider are fitted together through a resilient elastic element.

[0059] b. Set a certain number of insulators on the surface of the electrode discharge area. The insulators can generally be set in strips, meshes or particles. For the number of insulators, the following principles can generally be followed:

[0060] 1) The insulator is evenly distributed on the discharge surface;

[0061] 2) The number of insulators in any length direction of the discharge surface shall not be less than 2 (strips / particles);

[0062] 3) The gap between insulators shall not exceed 20 mm;

[0063] 4) The thickness of the insulator is 0.2 to 3 mm.

[0064] c. Set a limit structure on the slider to lock the maximum allowable removal amount of the product. The distance T between the limit structure and the workpiece and the amount to be removed have the following relationship:

[0065] T = amount to be removed - (0.1~0.3) mm

[0066] d. In order to enhance the guidance of the electrical machining direction, the m value should satisfy m>0.5n and m≥2cm.

[0067] After adopting the above improvement measures, the feeding of the electrode is controlled by the elastic connection structure. Under the action of the shrinkage and rebound of the connection structure, the gap between the workpiece and the tooling can be automatically adjusted as the remaining material to be processed is removed, and the optimal feeding speed is always maintained. At the same time, the insulating block also avoids direct contact between the electrode and the workpiece, ensuring the optimal gap. Combining the influence of the above two favorable conditions, the processing efficiency can be significantly improved while reducing the process complexity, and the production cost can be significantly reduced.

[0068] 2. Assembly and positioning of parts to be processed by electromechanical processing

[0069] The workpiece to be processed and the electromachining tooling are connected and assembled together through a resilient elastic structure. In this process, the preload force of the elastic element must be fully considered to ensure the smooth progress of the electromachining process. For the area to be removed in the axial direction and the area to be removed in the radial direction, the preload force in the elastic element has the following rules:

[0070] When the area to be removed is in the axial direction, the preload force F1 should be tensile stress and satisfy the following relationship:

[0071] F1-Q1*L≥50(N)

[0072] Among them, F1 is the pre-tightening tension of the connecting mechanism in the axial direction of the component to be processed; Q1 is the elastic coefficient; and L is the limit distance.

[0073] When the area to be removed is in the radial direction, the preload force F2 should be a compressive stress and satisfy the following relationship:

[0074] F2-Q2*T≥10(N)

[0075] Among them, F2 is the preload pressure of the elastic element in the radial direction of the component to be processed; Q2 is the elastic coefficient, and T is the limit distance. It should be noted that the number of elastic elements in the tooling is usually not less than 2. At this time, the preload force in each elastic element can be calculated by evenly distributing the total preload force.

[0076] 3. Implementation of the electrical machining process

[0077] Place the assembled and positioned workpiece and the electrical machining tooling in the electrolyte and apply current to complete the subsequent process. During the implementation process, the voltage setting value is no more than 8V and the current is unlimited.

[0078] The present invention provides a device for improving the efficiency of metal blind cavity electrical discharge machining, which can significantly reduce production costs while improving production efficiency and greatly reduce the demand for machine tools.

[0079] Although the content of the present invention has been described in detail through the above preferred embodiments, it should be appreciated that the above description should not be considered as a limitation of the present invention. After reading the above content, it will be apparent to those skilled in the art that various modifications and substitutions of the present invention will occur. Therefore, the protection scope of the present invention should be limited by the appended claims.

[0080] The contents not described in detail in the specification of the present invention belong to the common knowledge of the professionals in this field.

Claims

1. A device for improving the efficiency of electrical discharge machining of metal parts, characterized in that: include: An axial machining component is used for axial machining of a workpiece; the axial machining component comprises an electrode body, a hook component and a connecting structure; the electrode body comprises an electrode rod and a limit rod; the limit rod is vertically connected to the tail end of the electrode rod; the hook component is arranged at the tail of the workpiece to be machined; the connecting structure is used for locking the connection between the hook component and the limit rod, and a limit boss is arranged on the side of the limit rod close to the workpiece to be machined; a discharge area is arranged on the electrode rod, and discharge realizes the machining of the area to be machined.

2. A device for improving the efficiency of electric discharge machining of metal parts according to claim 1, characterized in that: It also includes a radial processing component for radially processing the workpiece to be processed; the radial processing component includes a radial electrode body, a slider and an elastic element; wherein the radial electrode body includes an electrode rod and a processing head; the processing head is located at one end of the motor rod; the processing head is symmetrically provided with two grooves along the radial direction of the workpiece; the slider is a T-shaped structure; one end of the slider is located in the groove, and the other end is provided with a discharge area, which contacts the area to be processed for discharge processing; the elastic element is located between the slider and the electrode body to achieve a clearance fit between the slider and the electrode body; at the same time, the elastic element achieves the fit between the workpiece to be processed and the slider.

3. A device for improving the efficiency of electric discharge machining of metal parts according to claim 1 or 2, characterized in that: The surface of the discharge area is evenly distributed with insulators; the insulators are arranged in strip, mesh or granular form; the number of insulators in any length direction of the discharge area is not less than 2; the gap b between the insulators is not greater than 20 mm; the thickness a of the insulator is 0.2 to 5 mm.

4. The device for improving the efficiency of electric discharge machining of metal parts according to claim 1, characterized in that: L=Q-δ; L is the limiting distance between the limiting boss and the boundary of the workpiece, Q is the thickness to be processed, δ is the allowance to be processed, δ=0.3~0.5mm.

5. The device for improving the efficiency of electric discharge machining of metal parts according to claim 1, characterized in that: h>0.5C, h is the height of the electrode rod, and C is the length of the electrode rod.

6. The device for improving the efficiency of electric discharge machining of metal parts according to claim 1, characterized in that: F1-Q1*L≥50; where F1 is the pre-tightening force of the connecting mechanism in the axial direction of the component to be processed; Q1 is the elastic coefficient; and L is the limit distance.

7. The device for improving the efficiency of electric discharge machining of metal parts according to claim 2, characterized in that: The gap between the slider and the radial electrode body is not less than 0.3 mm.

8. The device for improving the efficiency of electric discharge machining of metal parts according to claim 2, characterized in that: Limit rods are arranged on both sides of the slide block; the distance between the limit rods and the workpiece to be processed is T=Q1-β; Q1 is the thickness of the area to be processed, β is the allowance to be processed, β=0.1-0.3mm.

9. The device for improving the efficiency of electric discharge machining of metal parts according to claim 2, characterized in that: m>0.5n and m≥2cm; wherein, m is the distance between the contact point between the elastic element and the motor body and one end point of the slider in the groove when the elastic element is not compressed, and n is the contact surface length between the slider and the area to be processed.

10. The device for improving the efficiency of electric discharge machining of metal parts according to claim 2, characterized in that: F2-Q2*T≥10, where F2 is the preload pressure of the elastic element in the radial direction of the component to be processed; Q2 is the elastic coefficient, and T is the limit distance.

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