Metal surface microstructure mask electrolytic machining device and method based on variable-size composite tool electrode

Abstract

The invention discloses a metal surface microstructure mask electrolytic machining device and method based on a variable-size composite tool electrode, relates to the field of mask electrolytic machining, and aims to solve the problems that due to the fact that the machining area of an existing mask electrolytic machining area is large, the machined surface roughness is high; the device comprises a workpiece, a mask, a power supply, a variable-size electrode group and an electrolyte nozzle, a mask is arranged on the to-be-machined face of the workpiece, hollowed-out lines are formed in the mask, a variable-size electrode set is arranged above the mask, an anode of a power source is communicated with the workpiece, a cathode of the power source is communicated with the variable-size electrode set, and an electrolyte nozzle is arranged on the variable-size electrode set. The variable-size electrode group comprises a large-size electrode, a small-size electrode and an insulating resin sheet I; by switching the working area of the variable-size electrode set, rapid switching between efficient rough machining and finish machining capable of improving the surface quality is achieved, and the electrode set is used for metal surface electrolytic machining.

Description

Technical Field

[0001] The present invention relates to the field of mask electrolytic machining, and particularly to a mask electrolytic machining device and method for metal surface microstructures based on a variable-size composite tool electrode. Background Art

[0002] Electrolytic machining is a special machining technology for removing workpiece materials based on the principle of electrochemical anodic dissolution. It is not limited by the hardness, strength, toughness, etc. of the material and is suitable for machining various difficult-to-cut metals. Mask scanning electrolytic machining is a machining process of electrolytic machining. The non-machining area is protected by a mask, and the exposed machining area is removed under the action of the electrolytic principle to form microstructures on the workpiece surface. The microstructures on the surface of metal workpieces can be used to achieve surface functions such as lubrication and improved wear resistance, and have wide applications in industry. Mask scanning electrolytic machining can form a batch of microstructures on the surface of metal components, so it is the preferred manufacturing process for manufacturing metal surface microstructures.

[0003] During the scanning electrolytic machining process, increasing the current density in the machining area usually corresponds to a lower surface roughness. However, in order to obtain a higher machining efficiency, the machining area is usually larger, which results in a lower current density in the machining area, so the machining surface roughness is higher, and it is impossible to have both high machining efficiency and good surface quality. Summary of the Invention

[0004] In order to solve the problems in the existing mask electrolytic machining that the machining area is large, resulting in a higher machining surface roughness; and the machining area is small, resulting in a low machining efficiency, the present invention further provides a mask electrolytic machining device and method for metal surface microstructures based on a variable-size composite tool electrode to solve the problems raised in the above background art.

[0005] The technical solution of the present invention is as follows:

[0006] A mask electrolytic machining device for metal surface microstructures based on a variable-size composite tool electrode includes a workpiece, a mask, a power supply, a variable-size electrode group, and an electrolyte nozzle;

[0007] A mask is provided on the surface of the workpiece to be machined. The mask is provided with hollow patterns. Above the mask is a variable-size electrode group. The anode of the power supply is connected to the workpiece, and the cathode of the power supply is connected to the variable-size electrode group. An electrolyte nozzle is provided on the variable-size electrode group.

[0008] Further, the variable-size electrode group includes a large-size electrode, a small-size electrode, and an insulating resin sheet I;

[0009] The processing surfaces of the large-sized electrode and the small-sized electrode are adjacent to the mask. An insulating resin sheet Ⅰ separated by insulation is arranged between the large-sized electrode and the small-sized electrode. The large-sized electrode is connected to the cathode of the power supply through a large electrode switch, and the small-sized electrode is connected to the cathode of the power supply through a small electrode switch.

[0010] Further, the variable-sized electrode group includes parallel small electrode Ⅰ, parallel small electrode Ⅱ, parallel small electrode Ⅲ, parallel small electrode Ⅳ, and insulating resin sheet Ⅱ;

[0011] The processing surfaces of parallel small electrode Ⅰ, parallel small electrode Ⅱ, parallel small electrode Ⅲ, and parallel small electrode Ⅳ are adjacent to the mask. Insulating resin sheets Ⅰ separated by insulation are arranged between adjacent parallel small electrode Ⅰ, parallel small electrode Ⅱ, parallel small electrode Ⅲ, and parallel small electrode Ⅳ. Parallel small electrode Ⅰ is connected to the cathode of the power supply through switch Ⅰ, parallel small electrode Ⅱ is connected to the cathode of the power supply through switch Ⅱ, parallel small electrode Ⅲ is connected to the cathode of the power supply through switch Ⅲ, and parallel small electrode Ⅳ is connected to the cathode of the power supply through switch Ⅳ.

[0012] Further, the working surface length of the large-sized electrode is 600 mm and the width is 200 mm, and the working surface length of the small-sized electrode is 600 mm and the width is 100 mm.

[0013] Further, the working surface length of parallel small electrode Ⅰ, parallel small electrode Ⅱ, parallel small electrode Ⅲ, and parallel small electrode Ⅳ is 600 mm and the width is 100 mm.

[0014] Further, the inter-electrode gap between the working surfaces of the large-sized electrode and the small-sized electrode and the workpiece is 0.1 mm - 5 mm.

[0015] Further, the inter-electrode gap between the working surfaces of parallel small electrode Ⅰ, parallel small electrode Ⅱ, parallel small electrode Ⅲ, and parallel small electrode Ⅳ and workpiece 1 is 0.1 mm - 5 mm.

[0016] A mask electrolytic machining method for metal surface microstructures based on a variable-sized composite tool electrode, the method comprising the following steps:

[0017] Step 1, form a mask on the surface of the workpiece according to the microstructural characteristics of the metal component surface. Pass electrolyte into the inter-electrode gap between the tool electrode and the workpiece through an electrolyte nozzle. Turn on the large electrode switch and turn off the small electrode switch. Connect the large-sized electrode alone to the power supply. The large-sized electrode reciprocally scans on the workpiece along a predetermined path, and manufacture microstructures on the surface of the workpiece through electrolytic machining to complete the rough machining of the microstructures on the surface of the workpiece;

[0018] Step 2: After the rough machining of the microstructures is completed, disconnect the switch of the large electrode and connect the switch of the small electrode. Connect the small-sized electrode separately to the power supply. The small-sized electrode reciprocally scans on the workpiece along a predetermined path again to improve the surface quality of the microstructures on the workpiece surface.

[0019] Step 3: After the machining is completed, disconnect the power supply, stop supplying the electrolyte, and remove the large-sized electrode and the small-sized electrode from the working area.

[0020] The present invention has the following beneficial effects compared with the prior art:

[0021] 1. A metal surface microstructure mask electrolytic machining device based on a variable-size composite tool electrode is provided with a variable-size electrode group capable of changing the machining area to perform electrolytic machining on a mask workpiece. The variable-size electrode group includes a large-sized electrode and a small-sized electrode. First, the large-sized electrode is connected to the electrolytic circuit to perform rough machining on the mask workpiece; after the rough machining is completed, the small-sized electrode is connected to the electrolytic circuit to improve the surface quality of the workpiece. This tool electrode structure can achieve a rapid switching of the tool electrode size during the mask scanning electrolytic machining process. During the metal surface material removal stage, the large-sized electrode is used to efficiently and uniformly remove materials. After a large amount of material is removed, by switching the power supply circuit, the small-sized electrode is used to perform scanning electrolytic machining on the workpiece surface, thereby increasing the machining current density and using the high current density to improve the surface quality. Therefore, without changing the machining current, the machining area can be quickly changed, and then the current density of the machining area can be adjusted. High-efficiency machining is achieved through the machining surface of the large-sized electrode, and then the surface quality of the machined workpiece is improved by using the machining surface of the small-sized electrode.

[0022] 2. The variable-size electrode group is composed of parallel small electrodes I, parallel small electrodes II, parallel small electrodes III, and parallel small electrodes IV arranged in parallel. Among them, the parallel small electrodes I, parallel small electrodes II, parallel small electrodes III, and parallel small electrodes IV are respectively controlled by separate switches to connect to the electrolytic circuit. During rough machining, the parallel small electrodes I, parallel small electrodes II, parallel small electrodes III, and parallel small electrodes IV are all connected to the electrolytic circuit for large-area machining to complete the metal surface material removal process; during finish machining, one of the parallel small electrodes I, parallel small electrodes II, parallel small electrodes III, and parallel small electrodes IV is connected to the electrolytic circuit for small-area machining to complete the high-current density machining and improve the surface quality of the workpiece. The number of electrodes connected to the electrolytic circuit during rough machining and finish machining can be adjusted according to the complexity of the workpiece surface, which is suitable for different machining requirements. Description of the Drawings

[0023] Figure 1 is a schematic structural diagram of the first embodiment of the present invention;

[0024] Figure 2 is a schematic structural diagram of the second embodiment of the present invention.

[0025] In the figure: 1. Workpiece; 201. Mask; 202. Hollowed-out pattern; 3. Power supply; 4. Electrolyte nozzle; 501. Large-sized electrode; 502. Small-sized electrode; 503. Insulating resin sheet I; 504. Large electrode switch; 505. Small electrode switch; 601. Parallel small electrode I; 602. Parallel small electrode II; 603. Parallel small electrode III; 604. Parallel small electrode IV; 605. Switch I; 606. Switch II; 607. Switch III; 608. Switch IV; 609. Insulating resin sheet II. Specific embodiments

[0026] Specific embodiment 1: Refer to Figure 1 As shown, a mask electrolytic machining device for metal surface microstructures based on a variable-size composite tool electrode, this embodiment includes a workpiece 1, a mask 201, a power supply 3, a variable-size electrode group, and an electrolyte nozzle 4;

[0027] A mask 201 is arranged on the surface of the workpiece 1 to be machined, and a hollowed-out pattern 202 is formed on the mask 201. Above the mask 201 is a variable-size electrode group. The anode of the power supply 3 is connected to the workpiece 1, and the cathode of the power supply 3 is connected to the variable-size electrode group. An electrolyte nozzle 4 is arranged on the variable-size electrode group.

[0028] Specific embodiment 2: Refer to Figure 1 As shown, the variable-size electrode group of this embodiment includes a large-sized electrode 501, a small-sized electrode 502, and an insulating resin sheet I 503;

[0029] The machining surfaces of the large-sized electrode 501 and the small-sized electrode 502 are adjacent to the mask 201. An insulating resin sheet I 503 separated by insulation is arranged between the large-sized electrode 501 and the small-sized electrode 502. The large-sized electrode 501 is connected to the cathode of the power supply 3 through a large electrode switch 504, and the small-sized electrode 502 is connected to the cathode of the power supply 3 through a small electrode switch 505.

[0030] Specific embodiment 3: Refer to Figure 1 As shown, the working surface length of the large-sized electrode 501 in this embodiment is 600 mm, the width is 200 mm, the working surface length of the small-sized electrode 502 is 600 mm, and the width is 100 mm.

[0031] Specific embodiment 4: Refer to Figure 1 As shown, the inter-electrode gap between the working surfaces of the large-sized electrode 501 and the small-sized electrode 502 and the workpiece 1 is 0.1 mm - 5 mm.

[0032] Further, a variable-size electrode group capable of changing the machining area is provided to perform electrolytic machining on the mask workpiece. The variable-size electrode group includes a large-size electrode 501 and a small-size electrode 502. First, the large-size electrode 501 is connected to the electrolytic circuit to perform rough machining on the mask workpiece; after the rough machining is completed, the small-size electrode 502 is connected to the electrolytic circuit to perform finish machining on the mask workpiece. This tool electrode structure can achieve rapid switching of the tool electrode size during the mask scanning electrolytic machining process. During the metal surface material removal stage, the large-size electrode 501 is used to efficiently and uniformly remove the material. After a large amount of material is removed, by switching the power supply circuit, the small-size electrode 502 is used to perform scanning electrolytic machining on the workpiece surface, thereby increasing the machining current density and improving the surface quality using the high current density. Therefore, without changing the machining current, the machining area can be quickly changed, and then the current density in the machining area can be adjusted. High-efficiency machining is achieved through the machining surface of the large-size electrode 501, and then the surface quality of the machined workpiece is improved using the machining surface of the small-size electrode 502.

[0033] Specific Embodiment 5: Refer to Figure 2 As shown, the variable-size electrode group of this embodiment includes parallel small electrode I 601, parallel small electrode II 602, parallel small electrode III 603, parallel small electrode IV 604, and insulating resin sheet II 609;

[0034] The machining surfaces of parallel small electrode I 601, parallel small electrode II 602, parallel small electrode III 603, and parallel small electrode IV 604 are adjacent to the mask 201. Insulating resin sheet I 503 separated by insulation is provided between adjacent parallel small electrode I 601, parallel small electrode II 602, parallel small electrode III 603, and parallel small electrode IV 604. Parallel small electrode I 601 is connected to the cathode of the power supply 3 through switch I 605, parallel small electrode II 602 is connected to the cathode of the power supply 3 through switch II 606, parallel small electrode III 603 is connected to the cathode of the power supply 3 through switch III 607, and parallel small electrode IV 604 is connected to the cathode of the power supply 3 through switch IV 608.

[0035] Specific Embodiment 6: Refer to Figure 2 As shown, the working surface lengths of parallel small electrode I 601, parallel small electrode II 602, parallel small electrode III 603, and parallel small electrode IV 604 in this embodiment are 600 mm and the widths are 100 mm.

[0036] Specific Embodiment 7: Refer to Figure 2 As shown, the inter-pole gap between the working surfaces of parallel small electrode I 601, parallel small electrode II 602, parallel small electrode III 603, and parallel small electrode IV 604 and the workpiece 1 is 0.1 mm - 5 mm.

[0037] Furthermore, the variable-size electrode group is composed of parallel small electrodes Ⅰ601, parallel small electrodes Ⅱ602, parallel small electrodes Ⅲ603, and parallel small electrodes Ⅳ604 arranged in parallel. Among them, the parallel small electrodes Ⅰ601, parallel small electrodes Ⅱ602, parallel small electrodes Ⅲ603, and parallel small electrodes Ⅳ604 are respectively controlled by separate switches to connect to the electrolysis circuit. During rough machining, all of the parallel small electrodes Ⅰ601, parallel small electrodes Ⅱ602, parallel small electrodes Ⅲ603, and parallel small electrodes Ⅳ604 are connected to the electrolysis circuit for large-area machining to complete the metal surface material removal process; during fine machining, one of the parallel small electrodes Ⅰ601, parallel small electrodes Ⅱ602, parallel small electrodes Ⅲ603, and parallel small electrodes Ⅳ604 is connected to the electrolysis circuit for small-area machining to complete high-current density machining and improve the surface quality of the machined workpiece. The number of electrodes connected to the electrolysis circuit during rough machining and fine machining can be adjusted according to the complexity of the workpiece surface, which is suitable for different machining requirements.

[0038] Specific Embodiment VIII: Refer to Figure 1-2 As shown, a method for mask electrolytic machining of metal surface microstructures based on a variable-size composite tool electrode includes the following steps:

[0039] Step 1: Form a mask 201 on the surface of the workpiece according to the surface microstructure characteristics of the metal component. Pass electrolyte into the inter-electrode gap between the tool electrode and the workpiece 1 through the electrolyte nozzle 4. Turn on the large electrode switch 504 and turn off the small electrode switch 505. Connect the large-size electrode 501 alone to the power supply 3. The large-size electrode 501 reciprocally scans on the workpiece 1 along a predetermined path to manufacture microstructures on the workpiece surface through electrolytic machining, and complete the rough machining of the workpiece 1 surface microstructures.

[0040] Step 2: After the rough machining of the microstructures is completed, turn off the large electrode switch 504 and turn on the small electrode switch 505. Connect the small-size electrode 502 alone to the power supply 3. The small-size electrode 502 reciprocally scans on the workpiece 1 along a predetermined path again to improve the surface quality of the workpiece 1 surface microstructures.

[0041] Step 3: After the machining is completed, turn off the power supply 3, stop passing the electrolyte, and move the large-size electrode 501 and the small-size electrode 502 out of the working area.

[0042] The above embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those of ordinary skill in the art should understand that they can still modify the technical solutions recorded in the foregoing embodiments, or perform equivalent replacements for some of the technical features; and these modifications or replacements do not make the essence of the corresponding technical solutions deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A metal surface microstructure mask electrolytic machining device based on a variable-size composite tool electrode, characterized in that: It comprises a workpiece (1), a mask (201), a power source (3), a variable-size electrode group and an electrolyte nozzle (4); A mask (201) is provided on the surface to be processed of a workpiece (1), a hollow pattern (202) is provided on the mask (201), a variable-size electrode group is provided above the mask (201), an anode of a power source (3) is connected to the workpiece (1), a cathode of the power source (3) is connected to the variable-size electrode group, and an electrolyte nozzle (4) is provided on the variable-size electrode group.

2. The metal surface microstructure mask electrolytic machining device based on variable-size composite tool electrode according to claim 1 is characterized in that: The variable-size electrode group comprises a large-size electrode (501), a small-size electrode (502) and an insulating resin sheet I (503); The processing surfaces of the large-sized electrode (501) and the small-sized electrode (502) are adjacent to the mask (201), and an insulating resin sheet I (503) is provided between the large-sized electrode (501) and the small-sized electrode (502) for insulation separation. The large-sized electrode (501) is connected to the cathode of the power source (3) through the large electrode switch (504), and the small-sized electrode (502) is connected to the cathode of the power source (3) through the small electrode switch (505).

3. The metal surface microstructure mask electrolytic machining device based on variable-size composite tool electrode according to claim 1, characterized in that: The variable-size electrode group includes parallel small electrodes I (601), parallel small electrodes II (602), parallel small electrodes III (603), parallel small electrodes IV (604) and an insulating resin sheet II (609); The processing surfaces of the parallel small electrodes I (601), II (602), III (603) and IV (604) are adjacent to the mask (201), and an insulating resin sheet I (503) is provided between the adjacent parallel small electrodes I (601), II (602), III (603) and IV (604) for insulation separation. The parallel small electrode I (601) is connected to the cathode of the power supply (3) through the switch I (605), the parallel small electrode II (602) is connected to the cathode of the power supply (3) through the switch II (606), the parallel small electrode III (603) is connected to the cathode of the power supply (3) through the switch III (607), and the parallel small electrode IV (604) is connected to the cathode of the power supply (3) through the switch IV (608).

4. The metal surface microstructure mask electrolytic machining device based on variable-size composite tool electrode according to claim 2, characterized in that: The working surface of the large-size electrode (501) is 600 mm long and 200 mm wide, and the working surface of the small-size electrode (502) is 600 mm long and 100 mm wide.

5. The metal surface microstructure mask electrolytic machining device based on variable-size composite tool electrode according to claim 3 is characterized in that: The working surfaces of the parallel small electrode I (601), the parallel small electrode II (602), the parallel small electrode III (603) and the parallel small electrode IV (604) are 600 mm in length and 100 mm in width.

6. The metal surface microstructure mask electrolytic machining device based on variable-size composite tool electrode according to claim 2, characterized in that: The inter-electrode gap between the working surfaces of the large-size electrode (501) and the small-size electrode (502) and the workpiece (1) is 0.1 mm to 5 mm.

7. The metal surface microstructure mask electrolytic machining device based on variable-size composite tool electrode according to claim 3 is characterized in that: The inter-electrode gap between the working surfaces of the parallel small electrode I (601), the parallel small electrode II (602), the parallel small electrode III (603) and the parallel small electrode IV (604) and the workpiece (1) is 0.1 mm to 5 mm.

8. A processing method using the metal surface microstructure mask electrolytic processing device based on the variable-size composite tool electrode according to any one of claims 2, 4, and 6, characterized in that: The method comprises the following steps: Step 1: forming a mask (201) on the surface of the workpiece according to the surface microstructure features of the metal component, introducing electrolyte into the inter-electrode gap between the tool electrode and the workpiece (1) through the electrolyte nozzle (4), turning on the large electrode switch (504), turning off the small electrode switch (505), connecting the large-size electrode (501) to the power source (3) alone, scanning the large-size electrode (501) back and forth on the workpiece (1) along a predetermined path, manufacturing a microstructure on the surface of the workpiece through electrolytic machining, and completing the rough machining of the surface microstructure of the workpiece (1); Step 2: After the rough processing of the microstructure is completed, the large electrode switch (504) is turned off, the small electrode switch (505) is turned on, and the small-sized electrode (502) is connected to the power supply (3) separately, and the small-sized electrode (502) is scanned back and forth again on the workpiece (1) along a predetermined path to improve the surface quality of the microstructure on the surface of the workpiece (1); Step 3: After the processing is completed, disconnect the power supply (3), stop introducing the electrolyte, and move the large-sized electrode (501) and the small-sized electrode (502) out of the working area.

Images