A method for proportioning ultra-fine copper wire drawing dies

Abstract

This invention discloses a method for proportioning ultra-fine copper wire drawing dies, relating to the field of wire plastic compression technology. The method includes: collecting and preprocessing copper plasticity data; generating a compression decreasing sequence by combining the initial copper wire diameter and the activation energy of the slip system; extracting the compression diameter and compression gradient value from the compression decreasing sequence; calculating the initial curvature of the die inlet cone surface and the cone surface exit curvature using a matching algorithm; determining the sizing band gap size based on the initial curvature of the die inlet cone surface and the cone surface exit curvature; associating the initial curvature of the die inlet cone surface, the cone surface exit curvature, and the sizing band gap size as a three-dimensional reference for the die, generating a three-dimensional manufacturing reference drawing for the die; manufacturing a solid die assembly using the three-dimensional manufacturing reference drawing; and judging the die proportioning result. This invention achieves cross-scale precise coordination of ultra-fine copper wire drawing die proportioning through the synergistic effect of generating the compression decreasing sequence and calculating the die cone surface curvature.

Description

Technical Field

[0001] This invention relates to the field of wire plastic compression technology, and in particular to a method for proportioning dies for drawing ultra-fine copper wire. Background Technology

[0002] In the field of ultra-fine copper wire drawing die formulation, a process system is constructed based on a collaborative framework of material geometric compression models and empirical plasticity parameters. The industry standard method establishes a compression gradient model based on a historical copper material database. It generates a multi-pass reduction sequence using the initial wire diameter and preset compression ratio, calculates the initial curvature of the die inlet cone surface based on the average grain size and anisotropy index, and derives the curvature of the outlet cone surface using geometric constraint rules. After surface smoothness verification, the sizing band gap size is determined, ultimately driving 3D modeling software to generate die cavity manufacturing drawings. This technical process integrates fundamental materials science principles and manufacturing process data, forming a closed-loop design from parameter input to die physical processing, and has been widely applied in the mass production system of ultra-fine copper wire drawing.

[0003] However, existing technologies are insufficient in terms of compression ratio sequence optimization and geometric benchmark modeling. The generation of compression ratio decreasing gradients is often based on fixed ratio methods or linear distribution rules, which are difficult to dynamically respond to the non-uniform distribution characteristics of the activation energy of the slip system in copper materials, resulting in an uneven distribution of deformation energy during the compression process. The conical curvature calculation algorithm relies on static parameter matching in a preset rule base, which cannot effectively couple the dynamic iterative effect of the inlet and outlet curvature, causing deviations in the stability of the sizing band gap size. Summary of the Invention

[0004] In view of the aforementioned existing problems, the present invention is proposed.

[0005] Therefore, this invention provides a method for proportioning ultra-fine copper wire drawing dies to address the shortcomings in compression ratio sequence optimization and geometric benchmark modeling capabilities.

[0006] To solve the above-mentioned technical problems, the present invention provides the following technical solution:

[0007] In a first aspect, the present invention provides a method for proportioning an ultrafine copper wire drawing die, comprising: collecting copper material plasticity data and preprocessing it; the copper material plasticity data including historical copper material data, initial copper wire diameter, target copper wire diameter, average grain size, and slip system activation energy; combining the initial copper wire diameter and slip system activation energy to calculate the extreme value of the copper wire compression ratio, and dividing the compression ratio decrease gradient according to the extreme value of the compression ratio using the golden ratio rule to generate a compression decrease sequence; extracting the compression diameter and compression gradient value from the compression decrease sequence, and calculating the initial curvature of the die inlet cone surface and the cone surface exit curvature using a matching algorithm; determining the sizing band gap size based on the initial curvature of the die inlet cone surface and the cone surface exit curvature; associating the initial curvature of the die inlet cone surface, the cone surface exit curvature, and the sizing band gap size as a three-dimensional reference for the die, generating a three-dimensional manufacturing reference drawing for the die; using the three-dimensional manufacturing reference drawing for the die, manufacturing a physical die assembly, and performing ultrafine copper wire drawing verification for each pass to determine the die proportioning result.

[0008] As a preferred embodiment of the ultrafine copper wire drawing die proportioning method of the present invention, the following steps are taken: The extreme value of the copper wire's compressibility is calculated by combining the initial copper wire diameter and the activation energy of the slip system, and a decreasing compressibility gradient is generated by dividing the extreme value of the compressibility using the golden ratio to form a decreasing compressibility sequence.

[0009] By weighted fusion of the initial copper wire diameter and the activation energy of the slip system, the compressibility extremum is generated;

[0010] The extreme value of the compression ratio is used as the upper limit of copper wire compression. The upper limit is then discretely and proportionally divided according to the golden ratio to generate the compression gradient value.

[0011] The compressed gradient values ​​are rearranged in reverse order to generate a descending sorted sequence.

[0012] Based on the initial copper wire diameter, the diameter is reduced one pass at a time according to the compression gradient value of the descending sequence to generate a compression descending sequence.

[0013] As a preferred embodiment of the ultra-fine copper wire drawing die proportioning method of the present invention, the step of reducing the diameter successively according to the compression gradient value of the decreasing sequence based on the initial copper wire diameter to generate a compression decreasing sequence includes the following specific steps:

[0014] The initial copper wire diameter is used as the starting value for copper wire compression.

[0015] Extract the compression gradient value from the descending sorted sequence, and use the compression gradient value to perform a reduction transformation on the compression starting value to generate the compression diameter;

[0016] The iterative reduction transformation stops when the compressed diameter is less than or equal to the target copper wire diameter.

[0017] Combine all the compression diameters generated in the iterations according to the processing order, and output the compression decreasing sequence.

[0018] As a preferred embodiment of the ultra-fine copper wire drawing die proportioning method of the present invention, the specific steps of extracting the compression diameter and compression gradient value from the compression decreasing sequence, and calculating the initial curvature of the die inlet cone surface and the cone surface outlet curvature through a matching algorithm are as follows:

[0019] Extract the compressed diameter data column and the compressed gradient value data column from the compressed decreasing sequence to generate the diameter dataset and the gradient value dataset;

[0020] The initial curvature of the mold inlet cone surface is calculated using the strain hardening logarithmic function based on the diameter dataset and the average grain size.

[0021] The exit curvature of the die exit cone is calculated using the material flow elliptic function based on the gradient value dataset and the activation energy of the slip system.

[0022] As a preferred embodiment of the ultra-fine copper wire drawing die proportioning method of the present invention, the specific steps for determining the sizing zone gap size based on the initial curvature of the die inlet cone surface and the curvature of the cone surface outlet are as follows:

[0023] The initial curvature of the mold inlet cone and the exit curvature of the mold outlet cone are combined into a set of associated curvature parameters, and the pass number is marked for the set of associated curvature parameters.

[0024] Perform inverse conversion on each curvature parameter in the associated curvature parameter group to generate a curvature radius sequence;

[0025] Extract the end value of the mold inlet curvature radius sequence and the beginning value of the mold outlet curvature radius sequence from the curvature radius sequence, and calculate the absolute difference value;

[0026] Set a differential threshold based on historical copper material data;

[0027] If the absolute difference value is greater than or equal to the difference threshold, the absolute difference value is output as the sizing band gap size.

[0028] If the absolute difference value is less than the difference threshold, the difference threshold is output as the sizing band gap size.

[0029] As a preferred embodiment of the ultra-fine copper wire drawing die proportioning method of the present invention, the specific steps of associating the initial curvature of the die inlet cone surface, the curvature of the cone surface outlet, and the sizing band gap size as a three-dimensional reference for the die, and generating a three-dimensional manufacturing reference drawing for the die, are as follows:

[0030] Align the initial curvature of the mold inlet cone surface and the curvature of the cone surface outlet according to the pass number to generate a set of curvature center coordinates;

[0031] Based on the coordinate set of the curvature center, perform the transformation of the isocurvature center plane and output the axially symmetric space lattice.

[0032] The gap size of the sizing band is implanted into the inlet endpoint and outlet start point of the axially symmetric spatial lattice to generate a transition correction point sequence;

[0033] Connect the discrete points in the transition correction point column to form a continuous mold profile;

[0034] The 3D modeler is driven by the coordinate set of the continuous mold profile to generate 3D manufacturing reference drawings for the mold.

[0035] As a preferred embodiment of the ultrafine copper wire drawing die proportioning method of the present invention, the specific steps of performing isocurvature center plane transformation based on the curvature center coordinate set and outputting an axially symmetric spatial lattice are as follows:

[0036] Using the mold axis as a reference, the coordinate set of the curvature center is radially symmetrically pressed to generate a radially symmetrical lattice plate.

[0037] Axial tension compensation is performed on the radially symmetric lattice plate to output a center surface with equal curvature.

[0038] The center planes of equal curvature are output in the order of stretching passes to generate an axially symmetric space lattice.

[0039] As a preferred embodiment of the ultra-fine copper wire drawing die proportioning method of the present invention, the following steps are taken: A three-dimensional die manufacturing reference drawing is used to manufacture a solid die assembly, and the drawing verification of each pass of the ultra-fine copper wire is performed to determine the die proportioning result.

[0040] Using 3D mold manufacturing reference drawings, solid mold components are manufactured.

[0041] The solid mold assembly is assembled into the copper wire drawing equipment, and a number of drawing passes are performed with the initial copper wire diameter as the initial value.

[0042] Measure the diameter of the copper wire after each drawing pass, and compare the copper wire diameter with the compression diameter in the compression decreasing sequence to determine whether each drawing pass is qualified.

[0043] If each drawing pass is qualified, a signal indicating that the wire drawing die ratio verification has been sent to the personnel in charge.

[0044] If a drawing pass is not up to standard, locate the drawing position of the faulty pass and correct the mold at the drawing position.

[0045] In a second aspect, the present invention provides a computer device, including a memory and a processor, wherein the memory stores a computer program, wherein when the computer program is executed by the processor, it implements any step of the ultrafine copper wire drawing die proportioning method as described in the first aspect of the present invention.

[0046] Thirdly, the present invention provides a computer-readable storage medium having a computer program stored thereon, wherein: when the computer program is executed by a processor, it implements any step of the ultrafine copper wire drawing die proportioning method as described in the first aspect of the present invention.

[0047] The beneficial effects of this invention are as follows: By synergistically generating a compression reduction sequence and calculating the curvature of the die cone, precise cross-scale coordination of the die ratio for ultra-fine copper wire drawing is achieved. In generating the compression reduction sequence, the compression gradient value is discretized using the golden ratio, enabling dynamic matching between the material deformation energy distribution and the microscopic slip mechanism, eliminating plastic instability caused by misalignment accumulation. The initial curvature of the inlet cone is solved by the strain hardening logarithm function, combining the compression diameter sequence and the average grain size. Simultaneously, the outlet curvature of the outlet cone is analyzed by the material flow elliptic function based on the compression gradient value and the activation energy of the slip system, suppressing the rheological distortion effect in the transition zone of the cone. This, combined with the adaptive control of the sizing zone gap of the three-dimensional reference of the die, ultimately achieves full-process energy balance control for multi-pass copper wire drawing. Attached Figure Description

[0048] To more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings used in the following description of the embodiments will be briefly introduced. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0049] Figure 1 A flowchart of the formulation method for drawing ultra-fine copper wire.

[0050] Figure 2 The flowchart for generating a compressed decreasing sequence.

[0051] Figure 3 This is a flowchart showing the initial curvature of the inlet cone and the curvature of the outlet cone of the mold.

[0052] Figure 4 A flowchart for determining the clearance dimensions of a sizing band. Detailed Implementation

[0053] To make the above-mentioned objects, features and advantages of the present invention more apparent and understandable, the specific embodiments of the present invention will be described in detail below with reference to the accompanying drawings.

[0054] Many specific details are set forth in the following description in order to provide a full understanding of the invention. However, the invention may also be practiced in other ways different from those described herein, and those skilled in the art can make similar extensions without departing from the spirit of the invention. Therefore, the invention is not limited to the specific embodiments disclosed below.

[0055] Secondly, the term "one embodiment" or "embodiment" as used herein refers to a specific feature, structure, or characteristic that may be included in at least one implementation of the present invention. The phrase "in one embodiment" appearing in different places in this specification does not necessarily refer to the same embodiment, nor is it a single or selective embodiment that is mutually exclusive with other embodiments.

[0056] Reference Figures 1-4 As one embodiment of the present invention, this embodiment provides a method for proportioning ultra-fine copper wire drawing dies, including the following steps:

[0057] S1. Collect copper material plasticity data and perform preprocessing.

[0058] Copper plasticity data includes historical copper data, initial copper wire diameter, target copper wire diameter, average grain size, and slip system activation energy;

[0059] Specifically, historical copper data is obtained by querying structured historical records using SQL database query language. The structured historical records include measured values ​​of average grain size, anisotropy index, slip system activation energy inversion, wire diameter reduction sequence, measured values ​​of sizing zone gap size, and wire breakage rate statistics for copper materials in history. Index queries are performed based on copper batch codes to extract complete historical data chains for different copper types and store them as a two-dimensional data table sorted by pass number.

[0060] The initial copper wire diameter is obtained by collecting millimeter-level original diameter values ​​of the copper wire billet along the axial direction of the copper wire billet at equal intervals using a laser diameter measuring instrument. The axial coordinates of each measuring point are recorded simultaneously. The original diameter values ​​containing the coordinates are combined and simultaneously marked with the pass number to output the initial copper wire diameter.

[0061] The target copper wire diameter is obtained by extracting the design target diameter value and tolerance range from the dimensions marked on the wire product technical drawings;

[0062] The average grain size is obtained by scanning the surface of the copper wire blank with an optical microscope in multiple areas, capturing the grain distribution image, using image analysis tools to automatically calibrate the geometric contour of each grain and record the original measurement value of the equivalent diameter, and simultaneously saving the two-dimensional coordinate positioning mark of the grain in the observation area. Finally, the set of observation values ​​containing the grain position mark and the average grain size is output.

[0063] The slip system activation energy is generated by fixing the copper wire blank in a constant temperature chamber, applying axial tension using a stretching machine, scanning the crystal diffraction angle shift using an X-ray diffractometer, and analyzing the crystal diffraction angle shift using certified testing equipment.

[0064] Preprocessing includes outlier filtering, missing value imputation, unit unification, and data normalization;

[0065] Specifically, the abnormal data filtering process involves outlier detection on the collected copper plasticity data, setting dynamic threshold boundaries based on the physical characteristics and statistical distribution features of the data source, identifying abnormal copper plasticity data that deviates from the normal operating range, using a distribution consistency test algorithm to isolate invalid records for structured data fields, applying sliding window fluctuation analysis to capture abrupt changes for real-time measurement sequence data, marking all abnormal points with isolation markers and moving them into a buffer, and outputting the dataset to be repaired.

[0066] Missing value imputation involves filtering out abnormal data and outputting the dataset to be repaired. The imputation strategy is selected based on the spatiotemporal correlation characteristics of the data type: measurements with time series characteristics are imputed by linear interpolation of adjacent nodes, spatially distributed data are imputed by statistics of neighboring regions, and missing values ​​of attribute fields are assigned based on the cluster centers of similar data. Each imputation operation generates a data repair log to record the source value change path, forming a complete and continuous data chain.

[0067] Dimensional unification converts heterogeneous physical quantities in the complete data chain into the International System of Units (SI). Unit conversion mapping is implemented according to data attribute classification: length is unified to micrometer or millimeter base units, energy parameters are converted to kilojoules per mole scale, strain parameters are standardized to percentage or radian system. The conversion process strictly maintains the numerical accuracy and correlation identification of the original data, and outputs a standardized dataset with unit labels.

[0068] Data normalization involves dimensionless processing of the standardized dataset, using extreme value normalization to linearly map the copper plasticity data of each data dimension to the [0, 1] interval, independently performing scaling compression on discrete observations, and performing overall normalization on continuous time series data while maintaining the relative order. The processed continuous time series data retains the temporal structure relationship and spatial location identifier, and outputs a normalized multidimensional array that can be directly used for computational modeling.

[0069] S2. Combining the initial copper wire diameter and the activation energy of the slip system, calculate the extreme value of the compression ratio of the copper wire, and divide the compression ratio decreasing gradient according to the extreme value of the compression ratio using the golden ratio rule to generate a compression decreasing sequence.

[0070] By weighted fusion of the initial copper wire diameter and the activation energy of the slip system, the compressibility extremum is generated;

[0071] Specifically, the initial copper wire diameter is extracted and preprocessed, and the slip system activation energy is called simultaneously. The initial copper wire diameter is the original diameter of the copper wire before the drawing process begins. The slip system activation energy is the energy threshold required for each slip system to be activated during the plastic deformation process of the copper crystal structure. The initial copper wire diameter and slip system activation energy reflect the characteristics of the material in terms of macroscopic geometry and microscopic deformation mechanism, respectively. By setting weighting coefficients, the initial copper wire diameter and slip system activation energy are fused and calculated, and finally the limit value representing the maximum compressibility of the current copper wire is output. The limit value is the extreme value of the compressibility.

[0072] The formula for extreme compressibility is:

[0073] ;

[0074] in, The identifier for the pass number in copper wire compression. Indicates the first The maximum compressibility that a single copper wire can withstand, i.e., the extreme value of the compression ratio. Indicates the initial copper wire diameter. The weighting coefficient represents the initial copper wire diameter. Indicates the activation energy damping coefficient of the slip system. Indicates the activation energy of the slip system. Indicates the grain strengthening gain coefficient. Indicates the average grain size;

[0075] The extreme value of the compression ratio is used as the upper limit of copper wire compression. The upper limit is then discretely and proportionally divided according to the golden ratio to generate the compression gradient value.

[0076] The extreme value of the compression ratio is used as the upper limit of the deformation amount in the copper wire compression process. Based on the upper limit of the deformation amount using the golden ratio (e.g., 0.618), the iterative segmentation process is started with the golden ratio as the decreasing proportional coefficient. The first segmentation operation takes the ratio of the upper limit value to the golden ratio and outputs the first compression gradient value. The first compression gradient value is used as the new input to perform the second segmentation to generate the second compression gradient value. The segmentation process is repeated until the compression gradient value approaches the minimum compression threshold allowed by the process. The minimum compression threshold is set based on the wire breakage rate statistics in historical copper material data. All compression gradient values ​​generated by the iteration are integrated to form an unordered gradient set.

[0077] The compressed gradient values ​​are rearranged in reverse order to generate a descending sorted sequence.

[0078] Specifically, obtain all compressed gradient values ​​in the unordered gradient set, read the numerical value of each compressed gradient value in the unordered gradient set, sort all compressed gradient values ​​according to the numerical descending order rule, identify the largest compressed gradient value as the first element, the second largest compressed gradient value as the second element, and continue to sort according to the compressed gradient values ​​until the minimum value element is reached. After sorting, output a descending sorted sequence with monotonically decreasing characteristics.

[0079] The initial copper wire diameter is used as the starting value for copper wire compression.

[0080] Extract the compression gradient value from the descending sorted sequence, and use the compression gradient value to perform a reduction transformation on the compression starting value to generate the compression diameter;

[0081] Based on the descending sorting sequence formed by reverse rearrangement, the current maximum compression gradient value is extracted from the starting position of the descending sorting sequence. The compression gradient value represents the compression ratio that should be applied in the first pass. The compression starting value is adjusted according to the compression ratio to generate the first pass compression diameter. The first pass compression diameter represents the actual size of the copper wire after the first compression deformation.

[0082] The formula for compression diameter is:

[0083] ;

[0084] in, The identifier for the pass number in copper wire compression. Indicates the initial copper wire diameter. Indicates the first The diameter of the copper wire in each pass, i.e., the compression diameter. This represents the compression gradient value;

[0085] The iterative reduction transformation stops when the compressed diameter is less than or equal to the target copper wire diameter.

[0086] The newly generated first pass compression diameter is used as the new compression starting value for copper wire compression. The next compression gradient value is extracted in descending order of the compression gradient value elements in the sorted sequence. The reduction transformation is performed cyclically to generate the compression diameter of subsequent passes. The copper wire diameter value of the latest pass compression diameter is continuously monitored. When the copper wire diameter value is less than or equal to the target copper wire diameter (such as in the final stage of fine drawing), the iteration process is immediately terminated and the current pass is marked as the final deformation node.

[0087] Combine all the compression diameters generated in the iteration according to the processing order, and output the compression decreasing sequence;

[0088] All the compression diameters generated during the iteration process are arranged sequentially according to the actual drawing process to form a complete compression reduction sequence. Each item in the compression reduction sequence represents the diameter of the copper wire after a specific drawing pass, which can be used for subsequent curvature calculation and profile generation. At the same time, it provides a theoretical reference for multi-pass drawing tests in the mold verification stage.

[0089] S3. Extract the compression diameter and compression gradient value from the compression decreasing sequence, and calculate the initial curvature of the mold inlet cone and the curvature of the cone outlet using a matching algorithm.

[0090] Extract the compressed diameter data column and the compressed gradient value data column from the compressed decreasing sequence to generate the diameter dataset and the gradient value dataset;

[0091] Specifically, the complete record of the compressed decreasing sequence is called, data separation is performed, the compressed diameter values ​​corresponding to all track numbers are extracted to form independent data columns, the compressed gradient values ​​under the same track number are extracted synchronously to form parallel data columns, the compressed diameter data column is assigned a diameter dataset identifier, the compressed gradient value data column is assigned a gradient value dataset identifier, and a track number mapping index table of diameter dataset identifier and gradient value dataset identifier is established to form a structured storage of diameter dataset and gradient value dataset.

[0092] The initial curvature of the mold inlet cone surface is calculated using the strain hardening logarithmic function based on the diameter dataset and the average grain size.

[0093] By using the compressed diameter ordered sequence (such as the diameter values ​​of passes 1 to n) in the diameter dataset, the preprocessed average grain size is called. Based on the strain hardening theory of metal plastic deformation, the pass-by-pass reduction of the compressed diameter ordered sequence is converted into the cumulative true strain value. The strain hardening coefficient is corrected by the average grain size (e.g., the smaller the grain size, the more significant the hardening effect). The curvature change law of the metal flow trajectory in the inlet region is analyzed by the strain hardening logarithm function, and the parameter queue of the initial curvature of the mold inlet cone surface arranged in pass order is output.

[0094] The formula for the initial curvature of the mold inlet cone surface is:

[0095] ;

[0096] in, The identifier for the pass number in copper wire compression. Indicates the first The initial curvature of the die inlet cone surface for each pass. This represents the inlet curvature calculation coefficient set based on the hardening properties of copper. Indicates the initial copper wire diameter. Indicates the first The diameter of the copper wire in each pass, Indicates the average grain size. Indicates the first Average grain size per pass Indicates the inlet curvature correction constant;

[0097] The exit curvature of the die exit cone is calculated using the material flow elliptic function based on the gradient value dataset and the activation energy of the slip system.

[0098] By using the ordered sequence of compressed gradient values ​​in the gradient value dataset, the preprocessed activation energy of the slip system is called. Based on the spatial orientation distribution characteristics of the copper crystal slip system, the compressed gradient value sequence is mapped to the deformation energy release intensity between passes. The activation energy of the slip system is fused to quantify the anisotropic angle of metal flow. The streamline curvature distribution of the outlet elastic recovery zone is calculated through the material flow elliptic function. A parameter queue of the outlet cone curvature of the mold is generated according to the pass number.

[0099] The formula for the curvature of the mold exit cone surface is:

[0100] ;

[0101] in, The identifier for the pass number in copper wire compression. Indicates the first The exit cone curvature of the die exit for each pass. This represents the coefficient for calculating the exit curvature, set based on the hardening properties of copper. Indicates the first Pass compression gradient value, Indicates the activation energy of the slip system. This represents the baseline value of the activation energy of the slip system. This represents the exit curvature correction constant.

[0102] S4. Determine the sizing zone gap size based on the initial curvature of the cone surface at the mold inlet and the curvature of the cone surface at the mold outlet.

[0103] The initial curvature of the mold inlet cone and the exit curvature of the mold outlet cone are combined into a set of associated curvature parameters, and the pass number is marked for the set of associated curvature parameters.

[0104] Specifically, from the parameter queue of the initial curvature of the mold inlet cone and the parameter queue of the exit curvature of the mold outlet cone, extract the initial curvature of the mold inlet cone and the exit curvature of the mold outlet cone with the same pass number. Encapsulate the initial curvature of the mold inlet cone and the exit curvature of the mold outlet cone with the same pass number into data pairs. Arrange all data pairs in ascending order of pass number to form a related curvature parameter group. Mark the corresponding pass number identifier for all data pairs in the related curvature parameter group.

[0105] Perform inverse conversion on each curvature parameter in the associated curvature parameter group to generate a curvature radius sequence;

[0106] Iterate through all data in the associated curvature parameter group, and perform independent processing on the associated curvature parameter group encapsulated for each pass number. Take the mathematical reciprocal of the initial curvature of the mold inlet cone to generate the inlet curvature radius value, and simultaneously take the mathematical reciprocal of the outlet curvature of the mold outlet cone to generate the outlet curvature radius value. Re-encapsulate the inlet curvature radius value and the outlet curvature radius value into curvature radius data pairs according to the same pass number. Integrate the curvature radius data pairs of all passes to generate a curvature radius sequence that maintains the pass order.

[0107] Extract the end value of the mold inlet curvature radius sequence and the beginning value of the mold outlet curvature radius sequence from the curvature radius sequence, and calculate the absolute difference value;

[0108] The formula for the absolute difference is:

[0109]

[0110] in, The identifier for the pass number in copper wire compression. Indicates the first The absolute difference of the lanes, This represents the final value of the mold inlet curvature radius sequence. This represents the initial value of the mold exit curvature radius sequence. Indicates the identifier of the end value of the mold inlet curvature radius sequence. Indicates the starting value identifier of the mold exit curvature radius sequence. Indicates the mold inlet identifier. Indicates the mold exit identifier;

[0111] Set a differential threshold based on historical copper material data;

[0112] Specifically, based on historical copper material data, the statistical distribution characteristics of the measured values ​​of the sizing band gap size are obtained through SQL database queries. The median of the measured values ​​of the sizing band gap size is taken as the benchmark reference value, and a differential threshold is set.

[0113] If the absolute difference value is greater than or equal to the difference threshold, it is determined that the current curvature change degree meets the safety requirements, and the absolute difference value is directly output as the sizing band gap size.

[0114] If the absolute difference value is less than the difference threshold, the difference threshold is output as the sizing band gap size.

[0115] S5. Associate the initial curvature of the mold inlet cone surface, the curvature of the cone surface outlet, and the gap size of the sizing zone as the mold three-dimensional datum, and generate the mold three-dimensional manufacturing datum drawing.

[0116] Align the initial curvature of the mold inlet cone surface and the curvature of the cone surface outlet according to the pass number to generate a set of curvature center coordinates;

[0117] Specifically, the initial curvature of the mold inlet cone and the curvature of the cone exit with the same pass number are extracted. A three-dimensional coordinate system is established based on the mold axis. The initial curvature of the mold inlet cone for each pass is used as the spatial coordinate of the inlet curvature center point, and the exit curvature of the mold outlet cone for the same pass is used as the spatial coordinate of the exit curvature center point. The spatial coordinates of the inlet curvature center point and the spatial coordinates of the exit curvature center point are arranged in order of pass number to generate a set of curvature center coordinates.

[0118] Using the mold axis as a reference, the coordinate set of the curvature center is radially symmetrically pressed to generate a radially symmetrical lattice plate.

[0119] Using the mold axis as the rotational symmetry center axis, radial compression is performed. The center points of the spatial coordinates of the inlet curvature center point and the spatial coordinates of the outlet curvature center point of each pass are rotated and copied around the mold axis, and uniformly distributed in the circumferential direction to form a ring-shaped lattice. The ring-shaped lattices of all passes are integrated to generate a radially symmetrical lattice plate perpendicular to the mold axis.

[0120] Axial tension compensation is performed on the radially symmetric lattice plate to output a center surface with equal curvature.

[0121] Based on the evaluation of the distribution law of the annular lattice spacing in the direction of the mold axis, a positive stretching offset is applied to the roughing stage passes (such as the first 3 passes), and a reverse stretching offset is applied to the final passes of the fine drawing stage (such as the last 3 passes), outputting a center surface with continuous curvature transition.

[0122] The center planes of equal curvature are output in the order of stretching passes to generate an axially symmetric space lattice.

[0123] The gap size of the sizing band is implanted into the inlet endpoint and outlet start point of the axially symmetric spatial lattice to generate a transition correction point sequence;

[0124] Specifically, the gap size of the sizing belt is read, a negative axial offset is superimposed on the coordinate position of the inlet endpoint of the axially symmetric spatial lattice, and a positive axial offset is superimposed on the coordinate position of the outlet start point to generate an inlet endpoint and an outlet start point with position correction. The inlet endpoint and the outlet start point are inserted into the beginning and end of the axially symmetric spatial lattice to form a transition correction point series.

[0125] Connect the discrete points in the transition correction point column to form a continuous mold profile;

[0126] Extract the coordinates of all discrete points in the transition correction point series, perform point series fitting based on the non-uniform rational B-spline curve algorithm, take the mold axis direction as the parameter axis, the discrete point coordinates as the control points, and the curvature continuity as the constraint condition, connect the discrete points in the transition correction point series to form a smooth space curve, which serves as the continuous mold profile.

[0127] The coordinate set of the continuous mold profile drives the 3D modeler to generate 3D manufacturing reference drawings for the mold;

[0128] Load the spatial coordinate point set of the continuous mold profile, transform the coordinate set into a solid geometry through a 3D modeler, perform axial rotation sweep with the continuous mold profile as the reference contour path to generate the mold cavity solid, add sizing zone gap dimension tolerance mark and curvature variation range label based on the dimension calibration device; output a 3D manufacturing reference drawing of the mold containing complete machining features.

[0129] S6. Using the three-dimensional manufacturing reference drawings of the mold, manufacture the physical mold components and perform the drawing verification of each pass of the ultra-fine copper wire to judge the wire drawing mold ratio results.

[0130] Using 3D mold manufacturing reference drawings, solid mold components are manufactured.

[0131] The solid mold assembly is assembled into the copper wire drawing equipment, and a number of drawing passes are performed with the initial copper wire diameter as the initial value.

[0132] Specifically, the solid mold assembly is installed onto the mold fixing frame of the wire drawing equipment. The initial copper wire diameter is used as the blank input. The main shaft of the wire drawing equipment is started, and multi-stage drawing is performed in the order of passes defined by the compression decreasing sequence.

[0133] Measure the diameter of the copper wire after each drawing pass, and compare the copper wire diameter with the compression diameter in the compression decreasing sequence to determine whether each drawing pass is qualified.

[0134] After each drawing process is completed, a laser diameter gauge is used to scan and output the copper wire diameter in real time. The compressed diameter corresponding to the number of the compressed process is extracted from the compression decreasing sequence. The absolute deviation between the measured copper wire diameter and the compressed diameter is compared to determine whether each drawing process is qualified. For example, when the absolute deviation is ≤0.5μm, the process is marked as qualified; when it exceeds 0.5μm, the process is marked as unqualified. The judgment results of each process are recorded.

[0135] If each drawing pass is qualified, a signal indicating that the wire drawing die ratio verification has been sent to the personnel in charge.

[0136] When all the results of the test are qualified, the verification pass response mechanism is triggered, the green indicator light of the audible and visual alarm is activated in the constant light mode, the mold ratio verification pass text prompt is displayed on the control terminal screen, and the verification pass signal is pushed to the operator's handheld terminal.

[0137] If a pass drawing is not up to standard, locate the position of the unqualified pass drawing and correct the mold at the position of the pass drawing.

[0138] When a pass is found to be unqualified, the first unqualified pass number is located, the mold assembly corresponding to the pass number in the wire drawing equipment is disassembled, and the mold cavity is corrected based on the deviation value. For small deviations (e.g., 0.5-1μm), the sizing belt is finely ground with a diamond grinding head, and for larger deviations (e.g., >1μm), the conical surface is re-machined with curvature compensation. After correction, the parts are reassembled and a single pass drawing re-inspection is performed.

[0139] This embodiment also provides a computer device applicable to the ultra-fine copper wire drawing die proportioning method, including: a memory and a processor; the memory is used to store computer-executable instructions, and the processor is used to execute the computer-executable instructions to realize the ultra-fine copper wire drawing die proportioning method proposed in the above embodiment.

[0140] The computer device can be a terminal, comprising a processor, memory, communication interface, display screen, and input devices connected via a system bus. The processor provides computing and control capabilities. The memory includes non-volatile storage media and internal memory. The non-volatile storage media stores the operating system and computer programs. The internal memory provides an environment for the operation of the operating system and computer programs stored in the non-volatile storage media. The communication interface is used for wired or wireless communication with external terminals; wireless communication can be achieved through Wi-Fi, carrier networks, NFC (Near Field Communication), or other technologies. The display screen can be an LCD screen or an e-ink screen. The input devices can be a touch layer covering the display screen, buttons, a trackball, or a touchpad on the computer device's casing, or an external keyboard, touchpad, or mouse.

[0141] This embodiment also provides a storage medium storing a computer program that, when executed by a processor, implements the method for proportioning ultra-fine copper wire drawing dies as proposed in the above embodiments. The storage medium can be implemented by any type of volatile or non-volatile storage device or a combination thereof, such as Static Random Access Memory (SRAM), Electrically Erasable Programmable Read-Only Memory (EEPROM), Erasable Programmable Read Only Memory (EPROM), Programmable Red-Only Memory (PROM), Read-Only Memory (ROM), magnetic storage, flash memory, magnetic disk, or optical disk.

[0142] In summary, this invention achieves precise cross-scale coordination of die proportions for ultra-fine copper wire drawing by synergistically generating a compression reduction sequence and calculating the curvature of the die cone. In generating the compression reduction sequence, the golden ratio is used to discretize the compression gradient value, dynamically matching the material deformation energy distribution with the microscopic slip mechanism, eliminating plastic instability caused by misalignment accumulation. The initial curvature of the inlet cone is solved using the strain hardening logarithm function, combining the compression diameter sequence and the average grain size. Simultaneously, the outlet curvature of the outlet cone is analyzed using the material flow elliptic function based on the compression gradient value and the slip system activation energy, suppressing the rheological distortion effect in the cone transition zone. This, combined with adaptive control of the sizing zone gap in the three-dimensional reference of the die, ultimately achieves balanced energy control throughout the multi-pass copper wire drawing process.

[0143] It should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit it. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of the present invention without departing from the spirit and scope of the technical solutions of the present invention, and all such modifications or substitutions should be covered within the scope of the claims of the present invention.

Claims

1. A method for proportioning ultra-fine copper wire drawing dies, characterized in that: include, Copper plasticity data is collected and preprocessed; the copper plasticity data includes historical copper data, initial copper wire diameter, target copper wire diameter, average grain size, and slip system activation energy. By combining the initial copper wire diameter and the activation energy of the slip system, the extreme value of the copper wire's compressibility is calculated. Then, using the golden ratio rule, a decreasing compressibility gradient is generated based on the extreme value of the compressibility, resulting in a decreasing compressibility sequence. The specific steps are as follows: By weighted fusion of the initial copper wire diameter and the activation energy of the slip system, the compressibility extremum is generated; The extreme value of the compression ratio is used as the upper limit of copper wire compression. The upper limit is then discretely and proportionally divided according to the golden ratio to generate the compression gradient value. The compressed gradient values ​​are rearranged in reverse order to generate a descending sorted sequence. Based on the initial copper wire diameter, the diameter is reduced step by step according to the compression gradient value of the descending sort sequence to generate a compression descending sequence. The compression diameter and compression gradient values ​​are extracted from the compression decreasing sequence, and the initial curvature of the mold inlet cone and the curvature of the cone outlet are calculated by a matching algorithm. The sizing zone gap size is determined based on the initial curvature of the cone surface at the mold inlet and the curvature of the cone surface at the mold outlet. The initial curvature of the mold inlet cone surface, the curvature of the cone surface outlet, and the gap size of the sizing zone are associated as the mold's three-dimensional datum, generating a three-dimensional manufacturing datum drawing for the mold. Using the 3D manufacturing reference drawings for the mold, a physical mold component is manufactured, and the drawing verification of each pass of the ultra-fine copper wire is performed to determine the wire drawing mold ratio results.

2. The method for proportioning ultra-fine copper wire drawing dies as described in claim 1, characterized in that: The process involves reducing the diameter of the initial copper wire successively according to the compression gradient values ​​of the descending sorted sequence, based on the initial copper wire diameter, to generate a compression descending sequence. The specific steps are as follows: The initial copper wire diameter is used as the starting value for copper wire compression. Extract the compression gradient value from the descending sorted sequence, and use the compression gradient value to perform a reduction transformation on the compression starting value to generate the compression diameter; The iterative reduction transformation stops when the compressed diameter is less than or equal to the target copper wire diameter. Combine all the compression diameters generated in the iterations according to the processing order, and output the compression decreasing sequence.

3. The method for proportioning ultra-fine copper wire drawing dies as described in claim 1, characterized in that: The steps for extracting the compression diameter and compression gradient values ​​from the compression decreasing sequence, and calculating the initial curvature of the mold inlet cone and the curvature of the cone outlet using a matching algorithm are as follows: Extract the compressed diameter data column and the compressed gradient value data column from the compressed decreasing sequence to generate the diameter dataset and the gradient value dataset; The initial curvature of the mold inlet cone surface is calculated using the strain hardening logarithmic function based on the diameter dataset and the average grain size. The exit curvature of the die exit cone is calculated using the material flow elliptic function based on the gradient value dataset and the activation energy of the slip system.

4. The method for proportioning ultra-fine copper wire drawing dies as described in claim 1, characterized in that: The specific steps for determining the sizing zone gap size based on the initial curvature of the mold inlet cone and the curvature of the cone outlet are as follows: The initial curvature of the mold inlet cone and the exit curvature of the mold outlet cone are combined into a set of associated curvature parameters, and the pass number is marked for the set of associated curvature parameters. Perform inverse conversion on each curvature parameter in the associated curvature parameter group to generate a curvature radius sequence; Extract the end value of the mold inlet curvature radius sequence and the beginning value of the mold outlet curvature radius sequence from the curvature radius sequence, and calculate the absolute difference value; Set a differential threshold based on historical copper material data; If the absolute difference value is greater than or equal to the difference threshold, the absolute difference value is output as the sizing band gap size. If the absolute difference value is less than the difference threshold, the difference threshold is output as the sizing band gap size.

5. The method for proportioning ultra-fine copper wire drawing dies as described in claim 1, characterized in that: The steps for associating the initial curvature of the mold inlet cone surface, the curvature of the cone surface outlet, and the sizing band gap dimension as a three-dimensional reference for the mold, and generating a three-dimensional manufacturing reference drawing for the mold, are as follows: Align the initial curvature of the mold inlet cone surface and the curvature of the cone surface outlet according to the pass number to generate a set of curvature center coordinates; Based on the coordinate set of the curvature center, perform the transformation of the isocurvature center plane and output the axially symmetric space lattice. The gap size of the sizing band is implanted into the inlet endpoint and outlet start point of the axially symmetric spatial lattice to generate a transition correction point sequence; Connect the discrete points in the transition correction point column to form a continuous mold profile; The 3D modeler is driven by the coordinate set of the continuous mold profile to generate 3D manufacturing reference drawings for the mold.

6. The method for proportioning ultra-fine copper wire drawing dies as described in claim 5, characterized in that: The specific steps for performing an isocurvature center plane transformation based on the curvature center coordinate set and outputting an axially symmetric spatial point lattice are as follows: Using the mold axis as a reference, the coordinate set of the curvature center is radially symmetrically pressed to generate a radially symmetrical lattice plate. Axial tension compensation is performed on the radially symmetric lattice plate to output a center surface with equal curvature. The center planes of equal curvature are output in the order of stretching passes to generate an axially symmetric space lattice.

7. The method for proportioning ultra-fine copper wire drawing dies as described in claim 1, characterized in that: The process involves using 3D model drawings to manufacture physical mold components, and then performing drawing verification for each pass of the ultra-fine copper wire to determine the die ratio. The specific steps are as follows: Using 3D mold manufacturing reference drawings, solid mold components are manufactured. The solid mold assembly is assembled into the copper wire drawing equipment, and a number of drawing passes are performed with the initial copper wire diameter as the initial value. Measure the diameter of the copper wire after each drawing pass, and compare the copper wire diameter with the compression diameter in the compression decreasing sequence to determine whether each drawing pass is qualified. If each drawing pass is qualified, a signal indicating that the wire drawing die ratio verification has been sent to the personnel in charge. If a drawing pass is not up to standard, locate the drawing position of the faulty pass and correct the mold at the drawing position.

8. A computer device comprising a memory and a processor, wherein the memory stores a computer program, characterized in that: When the processor executes the computer program, it implements the steps of the ultra-fine copper wire drawing die proportioning method according to any one of claims 1 to 7.

9. A computer-readable storage medium having a computer program stored thereon, characterized in that: When the computer program is executed by the processor, it implements the steps of the ultra-fine copper wire drawing die proportioning method according to any one of claims 1 to 7.

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