Corrosion-resistant aluminum alloy wire cutting efficient machining power supply device

Abstract

The invention discloses an efficient machining power feeding device for corrosion-resistant aluminum alloy wire cutting, and belongs to the field of metal material machining. In order to solve the problems that aluminum alloy wires are frequently broken and the machining surface is rough when a traditional hard alloy conductive block is used for machining aluminum alloy, the device comprises a base, a wire cylinder, a clamping block, a U-shaped positioning clamping sleeve, an electrode column and a wave spring pressing piece and is used in cooperation with an upper wire guide wheel in a machine tool. The base is fixed to the godet wheel through threads, the wire cylinder rotates along with the godet wheel, the clamping block clamps the wire cylinder through the spring pressing piece, and the electrode column forms an electricity inlet loop. During application, the steps of fixing the base, connecting the wire cylinder, installing the clamping sleeve and the clamping block, assembling the spring pressing piece, fixing the electrode column and connecting a power supply are operated, and the wire guide wheel rotates to throw away aluminum oxide. According to the invention, the power supply mode is changed from the traditional fixed sliding friction into synchronous rotating contact, so that the problems of conductive block abrasion, unstable power supply, frequent wire breakage, rough machined surface and the like caused by aluminum oxide particles in aluminum alloy wire cutting are fundamentally solved, and the machining efficiency and quality are remarkably improved.

Description

Technical Field

[0001] This invention relates to the field of metal material sample processing technology, and more specifically, to a high-efficiency wire EDM power supply device for corrosion-resistant aluminum alloys. Background Technology

[0002] Currently, the power supply device commonly used in wire EDM machines is a cemented carbide conductive block. During use, the electrode wire continuously slides at high speed across the stationary cemented carbide conductive block to achieve the purpose of electrifying the electrode wire. There are two problems when using this type of conductive device to cut aluminum alloy materials: (1) During the aluminum alloy wire cutting process, the aluminum element (Al) in the material is prone to oxidation reaction in the environment of high temperature, water and oxygen, and then aluminum oxide particles (Al2O3) are generated and attached to the surface of the electrode wire. Since aluminum oxide is very hard, it is usually used as an abrasive and structural ceramic material. Therefore, the aluminum oxide particles attached to the surface of the electrode wire will continue to rub when the electrode wire and the conductive block move relative to each other, which will lead to accelerated wear of the surface of the conductive block and the formation of grooves. A large number of aluminum oxide particles will fill the grooves worn out when the electrode wire passes through the conductive block. Since aluminum oxide is a typical insulating material, it will cause the electrode wire and the conductive block to be sometimes energized and sometimes insulated, which will lead to spark discharge. This discharge effect accelerates the corrosion process of the conductive block. As the groove wears deeper, more aluminum oxide will be blocked, which will have a clamping force on the passing electrode wire, jamming the electrode wire in the groove, thus causing the electrode wire to break frequently. Currently, when cutting aluminum alloy samples, taking a 100mm×100mm×100mm aluminum alloy block as an example, if it is cut into two equal rectangular blocks, there may be 3-5 wire breakages. Each wire breakage means that the electrode wire needs to be replaced, and each wire replacement takes a lot of time. However, when cutting other materials such as steel and titanium alloys, one electrode wire can cut about 50 blocks of the same volume and requirements as the aluminum alloy block on average. (2) During the processing of aluminum alloy, a large number of alumina particles are generated. These alumina particles will adhere to the surface of the electrode wire, which will cause the electrode wire to lose its roundness. At this time, the contact surface of the conductive block will have grooves of various sizes due to the continuous friction of the alumina, and lose its flatness. Therefore, the electrode wire will lose stability during the processing of aluminum alloy, which will seriously affect the surface finish of the processed aluminum alloy.

[0003] Existing patent CN207372462U discloses a power supply device for an elastic tip in aluminum wire EDM. This device abandons the traditional long, strip-shaped conductive block, designing a compact unit comprising an elastic tip, a spring, an elastic pressure plate, and a base, which is mounted on the side of a guide wheel assembly. Its core principle is: through the continuous elastic force provided by the spring, the conductive tip is always pressed firmly against the end face or shoulder of the guide wheel. Current is conducted from an external power source through the elastic tip to the rotating guide wheel, and then from the guide wheel to the electrode wire in contact with it. This device shifts the current transmission interface from "electrode wire-fixed conductive block" to "elastic tip-rotating guide wheel." On the one hand, because the guide wheel rotates synchronously with the electrode wire, there is no macroscopic sliding friction between the electrode wire and the guide wheel, avoiding direct wear of the electrode wire; on the other hand, the elastic pressure ensures tight contact, improving conductivity stability to a certain extent. However, this device still has significant shortcomings: First, the elastic tip and the guide wheel assembly have point contact, resulting in a small contact area. After long-term use, the contact end of the elastic tip will become uneven due to wear, leading to a decrease in electrical stability. This instability is further amplified when alumina particles accumulate. Second, the device uses a cylindrical helical spring to provide axial clamping force, which can only ensure axial contact between the elastic tip and the guide wheel. It cannot cope with the radial vibration of the electrode wire during processing, and the electrode wire may still become out of round due to alumina adhesion, resulting in a rough machining surface. Third, the base is made of stainless steel and is quite heavy. Installing it next to the guide wheel assembly increases the load on the guide wheel and affects its rotational accuracy. Furthermore, the device does not have a structure for actively removing alumina particles. Alumina particles accumulate in the contact area between the guide wheel and the elastic tip, gradually aggravating poor contact and causing repeated wire breakage. In addition, the elastic tip, base, and elastic pressure plate are all clearance fits. Vibration during processing may cause radial displacement of the elastic tip, further affecting electrical stability and machining accuracy.

[0004] Therefore, in order to better solve these problems and improve the processing efficiency and quality of aluminum alloy wire EDM, there is an urgent need to develop an efficient, high-quality aluminum alloy wire EDM processing device and method that does not require machine tool modification and is easy to install. Summary of the Invention

[0005] In view of this, the present invention aims to propose a corrosion-resistant aluminum alloy wire EDM high-efficiency power supply device to solve the problems of rapid wear, unstable power supply, frequent wire breakage and poor processing quality in the existing cemented carbide conductive block power supply method.

[0006] To achieve the above objectives, the technical solution of the present invention is implemented as follows:

[0007] This invention discloses a corrosion-resistant aluminum alloy wire EDM high-efficiency power supply device, the power supply device comprising:

[0008] The base is connected to the wire guide wheel of the wire EDM machine, and the bottom of the base is provided with a conical cavity;

[0009] The wire spool is rotatably inserted into the central aperture of the base, and one end of the wire spool is connected to the guide wheel and rotates synchronously with the guide wheel.

[0010] A conductive clamping assembly is mounted on a base and contacts the surface of the wire drum.

[0011] An electrode input assembly is mounted on a base and is electrically connected to a conductive clamping assembly and an external power supply.

[0012] Furthermore, there are at least two sets of conductive clamping components, and the conductive clamping components are evenly arranged on the outer periphery of the wire drum.

[0013] Furthermore, the conductive clamping assembly includes a U-shaped positioning sleeve, a clamping block, and an elastic clamping element; the clamping block contacts the outer surface of the wire spool through the elastic clamping element.

[0014] Furthermore, the clamping block is provided with a cohesive arc groove, which is adapted to the outer circumferential surface of the wire cylinder and fully fits the outer surface of the wire cylinder.

[0015] Furthermore, the U-shaped positioning sleeve is fixed to the base, and the U-shaped positioning sleeve is provided with a U-shaped positioning through groove, in which the clamping block is accommodated.

[0016] Furthermore, the elastic clamping component is a wave spring plate, with one end of the wave spring plate connected to the base and the other end connected to the clamping block.

[0017] Furthermore, the electrode input assembly includes an electrode post bolt, an upper conductive ring, and a lower conductive ring.

[0018] Furthermore, the electrode post bolts press the upper and lower conductive rings onto the base, and the upper and lower conductive rings are electrically connected to the conductive clamping assembly.

[0019] Furthermore, the wave spring pressure plate includes a pressure plate positioning end and a pressure plate snapping end; the pressure plate positioning end is connected to the wave spring pressure plate positioning support provided on the base, and the pressure plate snapping end is engaged with the wave spring pressure plate snapping groove provided on the clamping block.

[0020] Furthermore, the base is made of insulating material, and the inner surface of the conical cavity does not contact the outer surface of the wire tube.

[0021] Compared with existing technologies, the corrosion-resistant aluminum alloy wire EDM high-efficiency power input device described in this invention has the following advantages:

[0022] (1) The power supply device of the present invention adopts a contact power supply design with synchronous rotation of the guide wheel and the wire drum. Combined with the centrifugal force generated by the high-speed rotation of the guide wheel, it can actively remove the alumina particles on the surface of the electrode wire and avoid contact abnormalities caused by particle accumulation. The surface contact design between the conductive clamping component and the wire drum realizes almost zero relative sliding between the power supply component and the moving electrode wire, effectively eliminating the severe friction and wear caused by the traditional fixed conductive block.

[0023] (2) The power input device of the present invention adopts a dual-path parallel power input design, forming an independent current input channel through the upper and lower conductive rings. Even if there is a momentary fluctuation in a single path, the current can still continue to be transmitted, which greatly improves the fault tolerance and stability of the power input device. At the same time, the continuous elastic force provided by the wave spring pressure plate in the conductive clamping assembly enables the clamping block to adaptively compensate for the deformation, vibration and wear of the wire drum, and always maintain a suitable and constant contact pressure, thereby ensuring a low and stable contact resistance during long-term dynamic operation.

[0024] (3) The base of the power supply device of the present invention is directly connected to the original guide wheel of the machine tool through the internal connecting thread, which is fully compatible with the original parts of the existing wire cutting machine tool. No structural modification or parameter adjustment of the machine tool is required, which greatly reduces the preparation time. Moreover, the base of insulating material can not only effectively prevent the risk of current leakage to other parts of the machine tool through the power supply device body, but also reduce the load on the guide wheel and improve its rotation accuracy. Attached Figure Description

[0025] The accompanying drawings, which form part of this invention, are used to provide a further understanding of the invention. The illustrative embodiments of the invention and their descriptions are used to explain the invention and do not constitute an undue limitation of the invention. In the drawings:

[0026] Figure 1 This is an exploded view of the power supply device described in this invention;

[0027] Figure 2 This is a front view of the power supply device described in this invention;

[0028] Figure 3 This is a schematic diagram of the internal structure of the power supply device described in this invention;

[0029] Figure 4 This is a schematic diagram of the installation of the power supply device and the guide wheel according to the present invention;

[0030] Figure 5 This is a schematic diagram of the structure of the power supply device and the guide wheel after assembly according to the present invention;

[0031] Figure 6 This is a schematic diagram of the clamping block described in this invention;

[0032] Figure 7This is a schematic diagram of the U-shaped positioning sleeve described in this invention;

[0033] Figure 8 This is a schematic diagram of the bottom structure of the base described in this invention.

[0034] Explanation of reference numerals in the attached figures:

[0035] 1. Wire spool; 2. Electrode post bolt; 3. Hexagonal pressure block; 4. Upper conductive ring; 5. Electrode post spacer; 6. Fixing bolt; 7. Conductive ring shim bushing; 8. Lower conductive ring; 9. U-shaped positioning sleeve; 10. Clamping block; 11. Wave spring pressure plate; 12. Base; 13. Wave spring pressure plate positioning support; 14. Guide wheel; 9-1. U-shaped positioning through groove; 9-2. Pressure wire hole; 10-1. Wave spring pressure plate slot; 10-2. Engaging arc groove; 11-1. Pressure plate positioning end; 11-2. Pressure plate snap-fit ​​end; 12-1. Center clear hole; 12-2. Internal connecting thread; 12-3. Conical cavity; 14-1. Inner wheel stud. Detailed Implementation

[0036] To make the above-mentioned objects, features and advantages of the present invention more apparent and understandable, specific embodiments of the present invention will be described in detail below with reference to the accompanying drawings. In addition, the orientations involved in the following specific embodiments are briefly explained: the directions or positional relationships indicated by "front", "rear", "up", "down", "left", "right", "top", "bottom", etc. mentioned in the embodiments refer to the orientations or positional relationships shown in the accompanying drawings, and the term "on" means directly or indirectly supported by the element.

[0037] It should be noted that, in the description of this invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection, an electrical connection, or a connection that allows for communication; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0038] This invention provides a corrosion-resistant, high-efficiency wire EDM power supply device for aluminum alloys, comprising:

[0039] The base 12 is connected to the wire guide wheel 14 of the wire cutting machine tool, and the bottom of the base 12 is provided with a conical cavity 12-3;

[0040] The wire spool 1 is rotatably inserted into the central light hole 12-1 of the base 12, and one end of the wire spool 1 is connected to the wire guide wheel 14 and rotates synchronously with the wire guide wheel 14.

[0041] A conductive clamping assembly is disposed on the base 12 and is in contact with the surface of the wire drum 1;

[0042] An electrode input assembly is mounted on the base 12 and is electrically connected to the conductive clamping assembly and an external power supply.

[0043] More specifically, the base 12 and the guide wheel 14 are connected by threads, and the wire drum 1 can pass through the base 12 without contact, and one end of it is connected to the guide wheel 14, thus forming a rigid whole that rotates synchronously with the guide wheel 14; the conductive clamping assembly contacts the outer surface of the wire drum 1 to form a stable sliding electrical contact interface; there are at least two sets of conductive clamping assemblies, and the conductive clamping assemblies are evenly arranged on the outer periphery of the wire drum 1 and distributed along the circumference of the wire drum 1; each set of conductive clamping assemblies contacts the surface of the wire drum 1 to form a cooperative pressing structure for the wire drum 1.

[0044] It should be noted that a single clamping component can easily cause radial displacement of the wire drum, while a multi-set symmetrical distribution design can offset the risk of displacement caused by processing vibration through balanced force distribution, ensuring that the wire drum 1 always remains coaxial with the guide wheel 14, and avoiding poor contact caused by eccentricity; at the same time, the collaborative clamping structure can disperse the contact pressure, avoid uneven wear of components caused by local stress concentration, and adapt to the high-frequency vibration conditions during aluminum alloy wire cutting.

[0045] The base 12 is directly connected to the existing wire guide wheel 14 of the machine tool. The wire drum 1 passes through the base 12 without contact, requiring no additional modification to the machine tool and adapting to various wire EDM machines. The base 12 is made of insulating material, and the conical cavity 12-3 achieves weight reduction and anti-interference design, which not only avoids stray current interference with machining accuracy and ensures operator safety, but also reduces the load on the wire guide wheel 14, improves its rotational accuracy, and further ensures the stability of machining quality. The wire drum 1 and the wire guide wheel 14 form a synchronously rotating rigid whole, eliminating the relative sliding friction between the traditional fixed conductive block and the electrode wire. At the same time, the wire guide wheel 1... The high-speed rotation of the 4 can actively remove alumina particles from the surface of the electrode wire, fundamentally solving the problem of electrode wire jamming and breakage caused by alumina accumulation, and ensuring the continuity of processing; multiple sets of symmetrically distributed conductive clamping components achieve balanced force through coordinated clamping, ensuring that the wire drum 1 and the wire guide wheel 14 always rotate coaxially, avoiding contact offset caused by processing vibration or unilateral force, and forming a stable sliding electrical contact interface with surface contact, which greatly reduces contact resistance fluctuations and eliminates spark discharge caused by poor contact, solving the core pain point of unstable power input in traditional power input methods.

[0046] Specifically, the conductive clamping assembly includes a U-shaped positioning sleeve 9, a clamping block 10, and an elastic clamping member; the clamping block 10 contacts the outer surface of the wire spool 1 through the elastic clamping member.

[0047] More specifically, the clamping block 10 is provided with a clasping arc groove 10-2, which is adapted to the outer peripheral surface of the wire drum 1 and fully fits the outer surface of the wire drum 1, ensuring sufficient contact area to achieve low resistance conductivity; the U-shaped positioning sleeve 9 is fixed on the base 12, and the U-shaped positioning sleeve 9 is provided with a U-shaped positioning through groove 9-1, in which the clamping block 10 is accommodated; the elastic clamping element is a wave spring pressure plate 11, one end of which is connected to the base 12 and the other end is connected to the clamping block 10, providing the clamping block 10 with a radial clamping force pointing towards the axis of the wire drum 1.

[0048] It should be noted that the wave spring pressure plate 11 includes a pressure plate positioning end 11-1 and a pressure plate engaging end 11-2; the pressure plate positioning end 11-1 is connected to the wave spring pressure plate positioning support 13 provided on the base 12, and the pressure plate engaging end 11-2 engages with the wave spring pressure plate slot 10-1 provided on the clamping block 10, thereby efficiently transmitting the elastic force of the wave spring pressure plate 11 to the clamping block 10; the U-shaped positioning sleeve 9 is preferably made of a material with good conductivity and certain structural strength, such as brass or copper, thereby reducing energy loss during current transmission and stably bearing the force of the clamping block 10 and the wave spring pressure plate 11, avoiding deformation after long-term use; the clamping block 10 is made of a material with high conductivity, low contact resistance and good wear resistance, such as copper or beryllium copper. The surface of its enclosing arc groove 10-2 can be silver-plated or gold-plated to further reduce contact resistance and enhance corrosion resistance, thereby achieving low-resistance and low-loss current transmission; the wave spring pressure plate 11 is made of a material with both excellent elasticity and conductivity, such as spring steel, and its surface can be copper-plated or nickel-plated to ensure good corrosion resistance while ensuring current transmission capacity.

[0049] Preferably, the U-shaped positioning groove 9-1 fits tightly with the clamping block 10, so that the clamping block 10 is accommodated in the U-shaped positioning groove 9-1 without loosening; the pressing plate positioning end 11-1 is an annular sleeve structure, and the pressing plate snap-fit ​​end 11-2 is a boss structure that matches the wave spring pressing plate snap-fit ​​groove 10-1, ensuring that the elastic force direction always points to the center of the spool 1.

[0050] The tight fit between the U-shaped positioning groove 9-1 and the clamping block 10, combined with the precise connection method of the wave spring pressure plate 11 using the "ring sleeve positioning end + boss snap-fit ​​end", ensures that the clamping block 10 does not loosen or shift, thus ensuring that the elastic force always points towards the center of the bobbin 1, and that the clamping arc groove 10-2 always fits tightly against the surface of the high-speed rotating bobbin 1. This elastic design has excellent self-adaptive ability, automatically compensating for dimensional changes in the bobbin 1 caused by thermal expansion, slight vibration, or long-term wear, thereby maintaining a constant and appropriate pressure under dynamic working conditions. This prevents poor contact and avoids abnormal heating and wear caused by excessive pressure. At the same time, the clamping arc groove 10-2 achieves a complete fit with the bobbin 1, and the use of highly conductive materials and silver / gold plating on the surface of the clamping block 10 significantly reduces contact resistance. The U-shaped positioning sleeve 9 itself also has excellent conductivity, which together reduces energy loss in current transmission, thereby avoiding spark discharge and component corrosion caused by local heating, and ensuring continuous low resistance and high efficiency in current transmission.

[0051] Specifically, the electrode input assembly includes an electrode post bolt 2, an upper conductive ring 4, and a lower conductive ring 8.

[0052] More specifically, the electrode post bolt 2 presses the upper conductive ring 4 and the lower conductive ring 8 onto the base 12, and the upper conductive ring 4 and the lower conductive ring 8 are electrically connected to the conductive clamping assembly; the electrode input assembly also includes a hexagonal pressure block 3, an electrode post spacer 5, and a conductive ring raising bushing 7; after the electrode post bolt 2 passes through the hexagonal pressure block 3, the upper conductive ring 4, the device housing, the electrode post spacer 5, the lower conductive ring 8, and the conductive ring raising bushing 7 in sequence, it is threadedly fixed to the threaded hole of the base 12, reliably pressing the upper conductive ring 4 and the lower conductive ring 8 onto the base 12, ensuring that the axial positioning of each component is accurate and there is no loosening gap.

[0053] It should be noted that the electrode post spacer 5 is made of insulating material such as polytetrafluoroethylene and is located between the upper conductive ring 4 and the lower conductive ring 8 to achieve physical separation and electrical insulation between the two. The upper conductive ring 4 and the lower conductive ring 8 are both annular conductors and are electrically connected to the U-shaped positioning sleeves 9 in different sets of conductive clamping assemblies through wires to form a dual-path parallel power supply structure that is independent and electrically connected in parallel. The hexagonal pressure block 3 and the conductive ring pad bushing 7 limit the conductive ring to prevent it from shifting or loosening during high-frequency vibration and ensure the stability of the current transmission path.

[0054] The power supply device of this invention constructs a dual-path parallel power supply structure through the combination of upper and lower double conductive rings. Even if there is a momentary contact fluctuation in one path, the current can still be stably transmitted through the other path, avoiding processing interruption caused by a single power supply path failure. This significantly reduces the probability of sudden shutdown and is suitable for the continuous production requirements of aluminum alloy batch production. In addition, the insulation design of the electrode post spacer 5 completely eliminates the risk of short circuit between the upper and lower conductive rings. The hexagonal pressure block 3, the conductive ring shim bushing 7, and the electrode post bolt 2 limit the conductive ring, ensuring that the conductive ring remains in a stable position during high-frequency processing vibration. This avoids poor contact or resistance fluctuation caused by vibration and ensures continuous and uniform power supply.

[0055] Specifically, the base 12 is made of insulating material, and the inner surface of the conical cavity 12-3 does not contact the outer surface of the wire cylinder 1.

[0056] Specifically, the base 12 is preferably made of high-strength engineering plastic, such as nylon; a central light hole 12-1 is provided on the top of the base 12; the conical cavity 12-3 is an inverted conical cavity machined at the bottom of the base 12, with its large diameter end facing the guide wheel 14, the inner surface of the conical cavity 12-3 is machined smooth, and the inner surface of the end facing the guide wheel 14 is machined with an internal connecting thread 12-2.

[0057] It should be noted that the guide wheel 14 is provided with an inner wheel stud 14-1, and the base 12 is connected to the inner wheel stud 14-1 on the guide wheel 14 through an internal connecting thread 12-2. Therefore, the power supply device and the original parts of the machine tool can be quickly and stably installed without any modification to the existing machine tool. The diameter of the central optical hole 12-1 is slightly larger than the outer diameter of the wire drum 1, so that when the wire drum 1 rotates, its outer surface and the inner wall of the optical hole of the base 12 always maintain a small annular gap, and the two have no mechanical contact.

[0058] The use of high-strength engineering plastic gives the base 12 excellent insulation properties, effectively preventing the risk of current leakage to other parts of the machine tool through the power supply device body. At the same time, the direct connection between the internal connecting thread 12-2 and the inner wheel stud 14-1 of the guide wheel 14 requires no modification to the existing machine tool, greatly improving the ease of installation. Furthermore, the engineering plastic material significantly reduces the overall weight of the base 12, and the hollowed-out weight-reduction design of the conical cavity 12-3 minimizes the load on the guide wheel 14 formed by the power supply device, ensuring the stability of the electrode wire movement. The non-contact fit between the central aperture 12-1 and the wire drum 1 effectively reduces the possibility of friction, wear, or seizing between the rotating wire drum 1 and the fixed base 12, ensuring that the wire drum 1 can rotate synchronously at high speed with the guide wheel 14 for a long time with stable and low resistance.

[0059] The present invention will be further described below with reference to specific embodiments:

[0060] Example 1

[0061] like Figures 1 to 8 As shown in the figure, this embodiment provides an installation process for a corrosion-resistant aluminum alloy wire EDM high-efficiency machining power supply device, including the following steps:

[0062] Mounting base: The base 12 of the power supply device is directly screwed onto the inner wheel stud 14-1 of the upper guide wheel 14 of the wire cutting machine through the inner connecting thread 12-2 at its bottom, and tightened to fix the base 12 of the entire power supply device.

[0063] Connecting the wire spool 1: Pass the wire spool 1 through the center hole 12-1 of the base 12 from above, and connect the end with the internal thread to the inner wheel stud 14-1 at the shaft end of the upper guide wheel 14 to ensure that the wire spool 1 can rotate synchronously and smoothly with the guide wheel 14;

[0064] Install the U-shaped positioning sleeve 9 and the clamping block 10: Place the U-shaped positioning sleeve 9 in the predetermined position of the base 12, and use the fixing bolt 6 to pass through its clamping thread hole 9-2 and screw it into the threaded hole of the base 12. First, tighten it to a half-tight state, that is, the U-shaped positioning sleeve 9 is not completely pressed. Then, insert the clamping block 10 radially into the U-shaped positioning through groove 9-1 of the U-shaped positioning sleeve 9, and ensure that the inner side of the clamping arc groove 10-2 of the clamping block 10 is initially in contact with the outer circle surface of the wire drum 1. Finally, tighten the fixing bolt 6 completely to secure the U-shaped positioning sleeve 9 to the base 12, and at the same time, fix the clamping block 10 radially to the base 12 and keep it in stable contact with the wire drum 1.

[0065] Assemble the elastic clamping component: Fit the clamping end 11-1 of the wave spring clamping plate 11 onto the wave spring clamping plate positioning support 13 on the base 12, and then clamp the clamping end 11-2 of the wave spring clamping plate 11 into the wave spring clamping plate slot 10-1 on the outside of the clamping block 10; at this time, the elastic deformation force of the wave spring clamping plate 11 will be applied to the clamping block 10, generating a continuous clamping force, forcing the clamping arc groove 10-2 of the clamping block 10 to press tightly against the surface of the wire drum 1, forming a stable sliding electrical contact;

[0066] Install the electrode input assembly: Pass the electrode post bolt 2 through the hexagonal pressure block 3, the upper conductive ring 4, the power input device housing, the electrode post spacer 5, the lower conductive ring 8, and the conductive ring shim bushing 7 in sequence, and then screw it into the threaded hole at the bottom of the base 12 and tighten it; during this process, the upper conductive ring 4 and the lower conductive ring 8 are reliably pressed to ensure that the current path is unobstructed.

[0067] Power on and begin processing: Connect the power cord to the upper conductive ring 4 to the pulse power output terminal of the machine tool; after checking that all components are securely installed, start the wire EDM machine. At this time, the pulse current will be stably transmitted along the current path of "external power supply - upper conductive ring 4 and wire - U-shaped positioning sleeve 9 - clamping block 10 - wire drum 1 - upper guide wheel 14 - electrode wire". When the machine tool is running, the upper guide wheel 14 drives the electrode wire to move at high speed and perform cutting operations. Its rotation can effectively remove alumina particles from the electrode wire, and because it moves synchronously with the electrode wire, there is no relative friction, thus achieving efficient, high-quality, and high-stability cutting of aluminum alloy materials.

[0068] Example 2

[0069] This embodiment aims to verify the practical application effect of the power supply device described in Embodiment 1.

[0070] To verify the effectiveness of the power supply device of this invention, 50 samples were compared and tested using a conventional conductive block (comparative example) and the power supply device of this invention (exemplary example). The samples were aluminum alloy blocks from the same batch, each measuring 100mm × 100mm × 100mm. Before processing, the surface condition of the aluminum alloy blocks was consistent and met the processing requirements. All aluminum alloy blocks were qualified parts to ensure the consistency of the test benchmark. A cutting path was set to cut them into two rectangular blocks of equal size. 50 samples were processed consecutively, and the test results are shown in the table below.

[0071] Table 1 Comparison of processing test results (Time: minutes)

[0072]

[0073] As shown in the table above, compared with the traditional conductive block power supply method, the power supply device of the present invention exhibits significant advantages in processing efficiency, processing stability, and processing quality: First, the preparation time is reduced from 220 minutes to 50 minutes, a reduction of 77.3%, indicating that the power supply device has good adaptability to existing machine tools and does not require complex modifications or debugging, further demonstrating its ease of installation; Second, the wire changing time in the embodiment is 0 minutes, while the wire changing time in the comparative example is as long as 940 minutes, indicating that the power supply device can actively remove alumina particles from the surface of the electrode wire by adapting to the original wire guide wheel 14 of the machine tool and using its high-speed rotation, while eliminating the relative friction between the traditional conductive block and the electrode wire, thus fundamentally preventing the frequent wire breakage caused by alumina accumulation and conductive block wear, effectively saving wire changing time; Moreover, compared with the comparative example, the processing time of the embodiment is reduced from 1185 minutes to 960 minutes. The total time and the time per piece were reduced by 57% and 57.1% respectively, indicating that the power supply device can achieve continuous and stable power transmission, and the processing process is not interrupted by wire breakage, ensuring the continuity and efficiency of the cutting operation, thus greatly improving the processing efficiency. Finally, the processing qualification rate of the embodiment reached 100%, which is 40 percentage points higher than the 60% of the comparative example. This shows that the power supply device of the present invention has stable power supply, which can effectively avoid the problems of electrode wire out-of-roundness and uneven processing surface, and ensure the consistency of processing quality of aluminum alloy workpieces.

[0074] In summary, the power supply device of this invention adopts a synchronous rotational contact power supply method. The wire drum 1 rotates synchronously with the guide wheel 14, fundamentally eliminating the relative sliding friction between the electrode wire and the power supply device. The centrifugal force of the guide wheel 14 actively removes alumina particles adhering to the electrode wire. The wave spring pressure plate 11 drives the clamping block 10 to form an elastically adaptive surface contact with the wire drum 1, ensuring constant contact pressure and no relative friction, significantly reducing contact resistance and component wear, and adapting to high-frequency machining vibration conditions. Furthermore, the dual-path parallel transmission constructed by the upper and lower conductive rings avoids machining interruptions caused by single-path failures, ensuring continuous and uniform power supply. This fundamentally solves the long-standing technical problems in aluminum alloy wire cutting caused by alumina particles, such as wear, wire breakage, and rough machining surfaces. While ensuring continuous and stable machining, it significantly improves machining efficiency and finished product quality, providing a practical and feasible new solution for high-efficiency and high-quality wire cutting of aluminum alloys.

[0075] While the present invention has been disclosed above, it is not limited thereto. Any person skilled in the art can make various alterations and modifications without departing from the spirit and scope of the invention; therefore, the scope of protection of the present invention should be determined by the scope defined in the claims.

Claims

1. A corrosion-resistant aluminum alloy wire EDM high-efficiency power input device, characterized in that, The power input device comprises: a base (12) connected with a wire guide wheel (14) of a wire cutting machine tool, and a conical hole cavity (12-3) provided at the bottom of the base (12); a wire cylinder (1) rotatably arranged in a central light hole (12-1) of the base (12), and one end of the wire cylinder (1) connected with the wire guide wheel (14) and synchronously rotated with the wire guide wheel (14); a conductive clamping assembly arranged on the base (12) and in surface contact with the wire cylinder (1); an electrode input assembly arranged on the base (12) and electrically connected with the conductive clamping assembly and an external power supply.

2. The power passing device according to claim 1, wherein The conductive clamping assembly is at least two groups, and the conductive clamping assemblies are uniformly arranged on the outer periphery of the wire cylinder (1).

3. The power passing device of claim 1, wherein The conductive clamping assembly comprises a U-shaped positioning sleeve (9), a clamping block (10) and an elastic compression member; the clamping block (10) is in contact with the outer surface of the wire cylinder (1) through the elastic compression member.

4. The power passing device according to claim 3, wherein The clamping block (10) is provided with a clamping arc-shaped groove (10-2) which is adapted to the outer periphery of the wire cylinder (1) and fully adheres to the outer surface of the wire cylinder (1).

5. The power passing device of claim 3, wherein The U-shaped positioning sleeve (9) is fixed on the base (12), and the U-shaped positioning sleeve (9) is provided with a U-shaped positioning through groove (9-1), and the clamping block (10) is accommodated in the U-shaped positioning through groove (9-1).

6. The power passing device of claim 3, wherein The elastic compression member is a wave spring pressing sheet (11), one end of the wave spring pressing sheet (11) is connected with the base (12), and the other end is connected with the clamping block (10).

7. The power passing device of claim 1, wherein The electrode input assembly comprises an electrode column bolt (2), an upper conductive ring (4) and a lower conductive ring (8).

8. The power passing device of claim 7, wherein The electrode column bolt (2) presses the upper conductive ring (4) and the lower conductive ring (8) on the base (12), and the upper conductive ring (4) and the lower conductive ring (8) are electrically connected with the conductive clamping assembly.

9. The power passing device of claim 6, wherein, The wave spring pressing sheet (11) comprises a pressing sheet positioning end (11-1) and a pressing sheet clamping end (11-2); the pressing sheet positioning end (11-1) is connected with a wave spring pressing sheet positioning support (13) provided on the base (12), and the pressing sheet clamping end (11-2) is engaged with a wave spring pressing sheet clamping groove (10-1) provided on the clamping block (10).

10. The power passing device of claim 1, wherein The base (12) is made of insulating material, and the inner surface of the conical hole cavity (12-3) is not in contact with the outer surface of the wire cylinder (1).

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