EDM machining technology is a machining method widely used in many fields such as mold manufacturing, aerospace, electronic devices, precision machinery, instrumentation, automobile manufacturing and light industry . This technology uses the instantaneous high temperature and explosive force generated by electric spark discharge to engrave and process the workpiece, thereby realizing the processing of complex shapes and high hardness materials. This article will introduce technical details, operational procedures, application areas and precautions in detail, aiming to provide reference for relevant practitioners.
1. Technical details
The core of EDM machining is to use pulse power to generate a discharge between the tool electrode and the workpiece electrode, and the metal material on the surface of the workpiece is eroded by temperature high instantaneous and explosive force generated by the discharge.During the discharge process, the tool electrode and workpiece electrode are immersed in a liquid medium with a certain degree of insulation, such as kerosene, mineral oil or deionized water . The automatic feed adjustment device of the machine tool controls the movement of the tool electrode to maintain a small discharge gap (usually 0.01~0.05mm) between the tool and the workpiece .
The size of the discharge space is crucial for the treatment effect. If the gap is too large, the medium cannot be decomposed and a spark discharge cannot be formed; if the gap is too small, it may cause carbon deposition and even arc discharge, affecting the processing quality and efficiency. Therefore, during the treatment process, the discharge space must be controlled to ensure the stability and continuity of the discharge.
In addition, the setting of the pulse power supply is also a key factor affecting the treatment effect. Parameters such as pulse width, pulse interval, open circuit voltage and spark sustain voltage should be reasonably adjusted according to the requirements of the processing material, processing precision and the effectiveness of the treatment. For example, during rough machining, a larger pulse width and a higher open circuit voltage can be used to increase the processing speed, while during finishing, the pulse width and open circuit voltage can be used to increase the processing speed. open circuit should be reduced to improve machining accuracy and surface quality.
2. Business process
The operational process includes several steps such as preparation, installation of electrodes, parameter adjustment, treatment start and further treatment.
During the preparation phase, the machine tool and work area must be cleaned, the integrity of the electrodes and fixtures checked and the required liquid media prepared. Then install the workpiece and electrode on the machine tool, and adjust the position and angle of the electrode to ensure machining accuracy and efficiency.
Then set the parameters of the pulse power supply according to the processing requirements, including pulse width, pulse interval, open circuit voltage, etc. At the same time, it is also necessary to establish an automatic feed adjustment device for the machine tool to control the moving speed and direction of the tool electrode.
After setting the parameters, you can start processing. During the processing process, it is necessary to carefully observe the working status and processing effect of the machine tool, and adjust the parameters and electrode positions timely to ensure the quality and performance. effectiveness of the treatment. At the same time, it is also necessary to pay attention to the height and temperature of the working fluid level, as well as the cooling and chip removal conditions of the machine tool.
Once treatment is completed, further processing is required. First of all, the workpiece and the electrode should be cleaned to remove metal particles and residue on the surface. Then the size and shape of the part are inspected to ensure processing accuracy and meet design requirements. Then carry out maintenance and servicing of the machine tool to extend its service life and maintain processing performance.
3. Application fields
EDM machining technology has a wide range of applications. In the field of mold manufacturing, this technology can process mold cavities and mold bodies of various complex shapes, thereby improving the precision and life of the mold. In the aerospace field, this technology makes it possible to process difficult-to-machine materials such as high-temperature alloys and titanium alloys, thus meeting the high precision and high strength requirements of aerospace devices. In the field of electronics and electrical appliances, this technology can process microscopic holes and complex shaped parts, thereby improving the reliability and performance of electronic devices. In addition, this technology can also be used in many fields such as precision machinery, instrumentation, automobile manufacturing and light industry to solve problems that cannot be solved by traditional cutting processing.
4. Precautions
When using an EDM machine for processing, you should pay attention to the following points:
1. Operators should work standing on an insulating plate with a withstand voltage of 20 kV or more. Electrode tools should not be touched during treatment.
2. Always keep electrical equipment clean and avoid moisture, so as not to reduce the insulation resistance and affect the normal operation of the machine tool.
3. The working fluid should not be mixed with flammable liquids such as gasoline to avoid sparks causing fires. The fuel tank must have sufficient circulating oil volume to limit the oil temperature within a safe range.
4. During processing, the working fluid level should be a certain distance (30-50mm) higher than the workpiece. If the fluid level is too low, the processing current will be large, which can easily cause a fire. Intrusion into the electrode holder must also be avoided.
5. Carry out processing within the permitted specifications of the machine tool and do not work with excessive weight or excessive stroke.
In summary, EDM machining technology is an efficient machining method with broad application prospects and development potential. When using this technology for treatment, you should master its technical details and operational procedures, and pay attention to relevant issues to ensure the quality and effectiveness of the treatment.
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