开槽宽度对遮蔽模板辅助电解线切割加工微沟槽的影响  

Influence of Notch Width on Micro Channel for Template Shielded Wire Electrochemical Machining

作　　者：詹顺达 郭钟宁[1,2] 罗红平 刘桂贤[1,2] 余浩 Zhan Shunda;Guo Zhongning;Luo Hongping;Liu Guixian;Yu Hao(School of Electromechanical Engineering,Guangdong University of Technology,Guangzhou 510006,China;Guangzhou Key Laboratory of Nontraditional Machining and Equipment,Guangzhou 510006,China)

机构地区：[1]广东工业大学机电工程学院,广州510006 [2]广州市非传统制造技术及装备重点实验室,广州510006

出　　处：《机械科学与技术》2018年第10期1531-1536,共6页Mechanical Science and Technology for Aerospace Engineering

基　　金：国家自然科学基金项目(U1601201);广东省科技计划项目(2017A010102010)资助

摘　　要：针对微沟槽结构难以高效低成本加工的问题,提出一种遮蔽模板辅助电解线切割加工新工艺。利用开有槽道的绝缘模板遮蔽工件非加工表面,对加工区域进行电场屏蔽和流场改善,实现场域离散式电解线切割加工,有效提高微沟槽的尺寸精度和加工稳定性,又比一般掩膜电解加工的深宽比更高。仿真分析了不同开槽宽度的影响,设计了专用夹具,进行了工艺实验。结果表明:使用直径0.3 mm的电极丝进行电解线切割加工,当开槽宽度W≤1 mm时,遮蔽模板可有效改善沟槽精度和表面质量。利用开槽宽度为1 mm的遮蔽模板和0.3 mm直径的电极丝,成功地在不锈钢工件表面加工出了宽981 μm,深1 058 μm的微沟槽。In order to solve the problems in high aspect ratio micro channel machining,a novel process of template shielded wire electrochemical machining(TSWECM)is presented.A novel special fixture was designed to restrict distribution of electric field and increase electrolyte flow rate in machining zone,then the removal of electrolytic products strengthened,the machining accuracy and process efficiency enhanced.The effects of the notch width on the machining were studied by using the simulation and experiment.The results show that under the notch width of template below 1 mm,the machining accuracy of micro channel increased.The micro channel with a width of 981μm and depth of 1 058μm was successfully fabricated on the stainless steel surface by using the presented TSWECM process,in which a notch width of shielding template of 1 mm and diameter of wire cathode of 0.3 mm were utilized.

关 键 词：电解线切割 遮蔽模板 开槽宽度 场域离散 微沟槽 

分 类 号：TG662[金属学及工艺—金属切削加工及机床]