Manufacturing method of movable mask for electrolytic machining

Abstract

The invention discloses a manufacturing method of a movable mask for electrolytic machining, and relates to a manufacturing method of a movable mask. The problems that an existing movable mask is complex in manufacturing process and cannot be tightly attached to the surface of a workpiece due to the complex structure are solved. According to the method, the hollow part of the movable mask is designed according to the size of a microstructure needing to be formed on the surface of a machined workpiece, a preset hollow structure is formed on a magnetic metal flat plate through chemical etching, laser cutting or wire cut electrical discharge machining, and after cleaning and drying, an insulating elastic coating is prepared on the metal flat plate. Therefore, the movable mask can be of a multi-layer structure, after the movable mask is placed on the machined workpiece, the movable mask and the workpiece can be tightly attached to or separated from each other by controlling the magnetic switch, and the method has high applicability to a complex mask plate, is good in universality and is convenient and rapid to manufacture. The invention belongs to the technical field of movable mask manufacturing.

Description

Technical Field

[0001] The present invention relates to a manufacturing method of a movable mask, specifically to a manufacturing method of a movable mask for electrolytic machining, belonging to the technical field of movable mask manufacturing. Background Art

[0002] The surface microstructure of metal components can achieve functions such as surface lubrication, drag reduction, and wear resistance improvement, and has extensive applications in industry. However, the surface microstructure has the characteristics of batch array, and the processing difficulty is high.

[0003] Mask scanning electrolytic machining can efficiently form surface microstructures on metal components, that is, using a mask to protect the non-processing area, and the exposed processing area is removed under the action of the electrolysis principle to form microstructures on the workpiece surface. However, the conventional process of forming a mask on the workpiece surface using photoresist has a long processing flow and requires subsequent stripping. The operation is complex and will have an adverse impact on the environment. Therefore, using a reusable movable mask for scanning electrolytic machining is more conducive to its extensive application in industry.

[0004] The movable mask is usually a thin sheet with a hollow structure on its surface. Its hollow structure needs to be customized according to the structural characteristics of the processed microstructure. It is attached to the workpiece surface to cover the non-processing area and prevent the non-processing area from being processed during electrolytic machining.

[0005] Therefore, during the mask scanning electrolytic machining process, in order to well protect the non-processing area, the movable mask must be closely attached to the surface of the processed workpiece. However, due to the thin thickness of the movable mask, its rigidity is very weak, and there is no clamping area inside, which means how to achieve a close fit between the movable mask and the workpiece surface is a key problem in high-quality mask scanning electrolytic machining; at the same time, when processing complex surface microstructures, the structure of the movable mask is also complex, and the structural differences between different movable mask plates are very large. The complicated manufacturing process is also a problem restricting its extensive application.

[0006] Therefore, providing a manufacturing method of a movable mask for solving the above technical difficulties has become an urgent problem for those skilled in the art at present. Summary of the Invention

[0007] Aiming at the above deficiencies of the prior art, the present invention further provides a manufacturing method of a movable mask for electrolytic machining.

[0008] The technical solution of the present invention is as follows: A manufacturing method of a movable mask for electrolytic machining is carried out according to the following steps:

[0009] Step 1: Machine a metal flat plate with the same predetermined size as the movable mask, and the metal flat plate is a magnetizable metal plate;

[0010] Step 2: Perform a hollowing design on the metal flat plate according to the microstructures on the surface of the workpiece to be processed, and then process the hollowed-out part;

[0011] Step 3: Clean and dry the metal flat plate;

[0012] Step 4: Prepare an insulating elastic coating on the surface of the metal flat plate.

[0013] The present invention has the following effects compared with the prior art:

[0014] According to the size of the microstructures to be formed on the surface of the workpiece to be processed, the present invention designs the hollowed-out part of the movable mask, and uses chemical etching, laser cutting or wire electrical discharge machining to form a predetermined hollowed-out structure on the magnetizable metal flat plate. After cleaning and drying, an insulating elastic coating is prepared on the metal flat plate. Therefore, a multi-layer structure of the movable mask can be realized. After the movable mask is placed on the workpiece to be processed, by controlling the magnetic switch, the tight fitting and separation of the movable mask and the workpiece can be realized. This method has strong applicability to complex mask plates, good versatility and is convenient and fast to manufacture. Description of the Drawings

[0015] Figure 1 is a schematic diagram of the manufacturing process of the movable mask;

[0016] Figure 2 is a cross-sectional schematic diagram of the metal flat plate 1 after the elastic coating is prepared.

[0017] In the figure: 1. Metal flat plate. Detailed Embodiments

[0018] The following further describes the technical solution of the present invention in conjunction with the drawings and through specific embodiments. Obviously, the following described embodiments are only a part of the embodiments of the present invention, rather than all of the embodiments. All other embodiments obtained by those of ordinary skill in the art based on the embodiments of the present invention without creative efforts shall fall within the protection scope of the present invention.

[0019] Detailed Embodiment 1: In combination with Figure 1 This embodiment is described. A manufacturing method of a movable mask for electrolytic machining in this embodiment is specifically carried out according to the following steps:

[0020] Step 1: Machine a metal flat plate 1, the metal flat plate 1 has the same predetermined size as the movable mask, and the metal flat plate is a magnetizable metal plate;

[0021] Step 2: Perform a hollowing design on the metal flat plate 1 according to the microstructures on the surface of the workpiece to be processed, and then process the hollowed-out part, and the arrangement of the hollowed-out part is the same as the microstructures on the surface of the workpiece to be processed;

[0022] Step 3: cleaning and drying the metal plate 1;

[0023] Step 4: Prepare an insulating elastic coating on the surface of the metal plate 1.

[0024] Furthermore, if Figure 2 As shown, in this embodiment, in order to make the elastic coating more fully cover the hollow part, in the process of processing the hollow part in step 2, the outer contour size of the hollow part is appropriately increased (even if the size of the hollow part is larger than the size of the microstructure), and after the elastic coating is prepared on the surface of the metal plate 1, the metal plate 1 is finely processed (such as by milling) to remove the excess elastic coating attached to the hollow part. Considering the corrosion effect on the electrolysis side (i.e., the workpiece being processed), the outer contour size of the hollow part after fine processing is slightly smaller than the microstructure size of the surface of the workpiece being processed (usually 50μm to 500μm smaller than the microstructure size in actual engineering), and the side elevation of the hollow part can also be fully covered by the elastic coating.

[0025] Specific implementation method 2: Combination Figure 1 To explain this embodiment, in step 1 of this embodiment, the material of the metal plate 1 is S136 die steel or spring steel.

[0026] Furthermore, the metal plate 1 is a rectangular metal plate with a side length of 300 mm and a thickness of 1 mm.

[0027] Furthermore, the metal plate 1 is processed by laser cutting.

[0028] Other components and connection methods are the same as those in the first embodiment.

[0029] Specific implementation method three: Combination Figure 1 To illustrate this embodiment, in step 2 of this embodiment, the hollowed-out portion of the metal plate 1 is processed by chemical etching, laser cutting or wire electric discharge cutting.

[0030] Other components and connection methods are the same as those in the first or second embodiment.

[0031] Specific implementation method four: Combination Figure 1 To illustrate this embodiment, in step 4 of this embodiment, the elastic coating is a silicone layer, and the thickness of the silicone layer is 100 to 1000 μm.

[0032] The specific preparation process of the silicone layer is: spraying the sprayable silicone as the raw material for several times, alternately spraying the two sides of the metal plate 1; preferably, after spraying the silicone on one side, naturally air dry for 30 minutes, turn the metal plate 1 over, and then spray the other side of the metal plate 1, and repeat this process until the predetermined thickness is reached.

[0033] Or install the metal flat plate 1 in the injection mold, and prepare the silica gel on the surface of the metal flat plate 1 by injection molding. In the specific application process, the staff can select the above preparation method according to the specific situation.

[0034] Other compositions and connection methods are the same as those in the first, second or third specific embodiments.

[0035] The present invention has been disclosed in the above preferred embodiments, but it is not intended to limit the present invention. Any person skilled in the art, without departing from the content of the technical solution of the present invention, any simple modification, equivalent change and modification made to the above embodiments according to the technical essence of the present invention still fall within the scope of the technical solution of the present invention.

Claims

1. A method for manufacturing a movable mask for electrolytic machining, characterized in that: The method proceeds as follows: Step 1: Processing a metal plate (1), wherein the metal plate (1) has the same predetermined size as the movable mask, and the metal plate (1) is a magnetically attractable metal plate; Step 2: hollowing out the metal plate (1) according to the microstructure of the surface of the workpiece being processed, and then processing the hollowed-out part; Step 3: cleaning and drying the metal plate (1); Step 4: Prepare an insulating elastic coating on the surface of the metal plate (1).

2. The method for manufacturing a movable mask for electrolytic machining according to claim 1, characterized in that: The material of the metal plate (1) in step 1 is S136 die steel or spring steel.

3. The method for manufacturing a movable mask for electrolytic machining according to claim 1, characterized in that: In the step 1, the metal plate (1) is processed by laser cutting.

4. The method for manufacturing a movable mask for electrolytic machining according to claim 1, characterized in that: In the second step, the hollowed-out portion of the metal plate (1) is processed by chemical etching, laser cutting or electric spark wire cutting.

5. The method for manufacturing a movable mask for electrolytic machining according to claim 1, characterized in that: In the step 4, the elastic coating is a silicone layer, and the thickness of the silicone layer is 100 to 1000 μm.

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