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中走丝处理方法

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中走丝处理方法

发布日期:2016-04-21 00:00 来源:http://hzjxy-jdfy.cn 点击:

对于线切(qie)割(ge)(ge)(ge)(ge)(ge)工(gong)(gong)(gong)(gong)(gong)件(jian)(jian)余(yu)(yu)留(liu)部位(wei)切(qie)割(ge)(ge)(ge)(ge)(ge)的(de)(de)多次加(jia)(jia)工(gong)(gong)(gong)(gong)(gong),首先必须解决被加(jia)(jia)工(gong)(gong)(gong)(gong)(gong)工(gong)(gong)(gong)(gong)(gong)件(jian)(jian)的(de)(de)导(dao)电(dian)(dian)(dian)问题,因为在(zai)高(gao)精度线切(qie)割(ge)(ge)(ge)(ge)(ge)加(jia)(jia)工(gong)(gong)(gong)(gong)(gong)中,线电(dian)(dian)(dian)极的(de)(de)行(xing)(xing)走路线可能需(xu)要沿加(jia)(jia)工(gong)(gong)(gong)(gong)(gong)轨(gui)迹往复(fu)行(xing)(xing)走多次,才能保(bao)证被加(jia)(jia)工(gong)(gong)(gong)(gong)(gong)工(gong)(gong)(gong)(gong)(gong)件(jian)(jian)具有较高(gao)表面粗糙度和表面精度,这时线切(qie)割(ge)(ge)(ge)(ge)(ge)加(jia)(jia)工(gong)(gong)(gong)(gong)(gong)是靠工(gong)(gong)(gong)(gong)(gong)件(jian)(jian)余(yu)(yu)留(liu)部位(wei)起到导(dao)电(dian)(dian)(dian)作用以(yi)保(bao)障电(dian)(dian)(dian)加(jia)(jia)工(gong)(gong)(gong)(gong)(gong)正常(chang)进行(xing)(xing)。但在(zai)进行(xing)(xing)工(gong)(gong)(gong)(gong)(gong)件(jian)(jian)余(yu)(yu)留(liu)部位(wei)的(de)(de)切(qie)割(ge)(ge)(ge)(ge)(ge)加(jia)(jia)工(gong)(gong)(gong)(gong)(gong)时,若(ruo)第一次切(qie)割(ge)(ge)(ge)(ge)(ge)即切(qie)下工(gong)(gong)(gong)(gong)(gong)件(jian)(jian)余(yu)(yu)留(liu)部位(wei),将会导(dao)致(zhi)被切(qie)割(ge)(ge)(ge)(ge)(ge)部分(fen)与母体(ti)分(fen)离,以(yi)致(zhi)导(dao)电(dian)(dian)(dian)回路中断,无法进行(xing)(xing)继续加(jia)(jia)工(gong)(gong)(gong)(gong)(gong),所以(yi)从(cong)线切(qie)割(ge)(ge)(ge)(ge)(ge)加(jia)(jia)工(gong)(gong)(gong)(gong)(gong)的(de)(de)条件(jian)(jian)性和延续性考虑,必须使工(gong)(gong)(gong)(gong)(gong)件(jian)(jian)余(yu)(yu)留(liu)部位(wei)即便在(zai)多次切(qie)割(ge)(ge)(ge)(ge)(ge)的(de)(de)情况下也能保(bao)持与母体(ti)之间正常(chang)导(dao)电(dian)(dian)(dian)的(de)(de)要求。

为了(le)实现上述目的,操(cao)作(zuo)(zuo)工人(ren)力(li)图营(ying)造(zao)人(ren)为环境(jing)和(he)条件来满足导电要(yao)求,即(ji)当工作(zuo)(zuo)人(ren)员在(zai)(zai)操(cao)作(zuo)(zuo)电火花线切(qie)割(ge)机遇到切(qie)割(ge)工件余(yu)留部(bu)位时,可采用在(zai)(zai)被切(qie)割(ge)部(bu)分和(he)母体之间(jian)粘铜片和(he)在(zai)(zai)切(qie)割(ge)间(jian)隙中(zhong)塞铜片的处理方(fang)法来造(zao)成(cheng)人(ren)为的定位条件和(he)导电条件,使是火花加工得(de)以继(ji)续进(jin)行,其(qi)具体做法与技巧如下:

(1)在(zai)被切割(ge)部(bu)分与母体材料之间粘贴连接(jie)铜(tong)片。其目的(de)(de)是使(shi)工件(jian)余留部(bu)分在(zai)切割(ge)时与母体材料相连固定,保证线切割(ge)有(you)良好的(de)(de)定位(wei)条件(jian),从而保障工件(jian)有(you)优异的(de)(de)加工质量(liang),这可依照以(yi)下(xia)步骤进行(xing):

①首先(xian)根据(ju)加(jia)(jia)工工件(jian)的大小(xiao)把薄(bo)铜片(厚度根据(ju)线电极(ji)情况和加(jia)(jia)工部(bu)(bu)位(wei)形状而定(ding))剪成(cheng)长条(tiao)形,然后折叠(die),井(jing)保证折叠(die)部(bu)(bu)分一长一短。

②然后把铜片折叠的弯曲(qu)部分用小手锤锤平,并用什锦锉(cuo)修(xiu)理(li)成楔形;

③再把经以上(shang)处理的(de)铜片塞到线电极加工所形成的(de)缝隙里,同时在工件该部分(fen)的(de)表面滴上(shang)502胶(jiao)水(即环(huan)氧树脂瞬时快干胶(jiao))。

由于切(qie)割(ge)时,电火(huo)花线切(qie)割(ge)机冲水使工(gong)件(jian)所受压力(li)较大,若(ruo)单(dan)纯用铜(tong)片(pian)(pian)塞(sai)紧来保(bao)证导(dao)(dao)电和固(gu)定,容易产生以下问题:(a)铜(tong)片(pian)(pian)塞(sai)得太松,担心固(gu)定不可靠、导(dao)(dao)电不稳(wen)定;(b)铜(tong)片(pian)(pian)塞(sai)得太紧,又担心损伤工(gong)件(jian)表面、破坏形位公差(cha),所以采用502胶水来保(bao)证被切(qie)割(ge)部(bu)分与母体材料固(gu)定;

④在将铜片塞进加工(gong)部(bu)位时,应注(zhu)意是:用502胶(jiao)(jiao)水粘贴连接(jie)铜片时应远(yuan)离工(gong)件(jian)余留部(bu)件(jian)处(chu),以免502胶(jiao)(jiao)水渗到,造成绝缘。此外粘贴连接(jie)铜片的位置应考虑对(dui)称(cheng)分布,且应保(bao)证同(tong)时塞紧,避(bi)免工(gong)件(jian)发生(sheng)偏移,以致影(ying)响工(gong)件(jian)加工(gong)质量。保(bao)证被切割工(gong)件(jian)余留部(bu)位形状的正确性(xing)和精度的可靠(kao)性(xing)。

(2)在被切割(ge)部分与(yu)母体(ti)材料之间(jian)填(tian)充(chong)导(dao)电(dian)(dian)铜(tong)(tong)片(pian)(pian)(pian)。把经(jing)折(zhe)叠、剪齐、锤平(ping)和修锉的(de)(de)(de)薄铜(tong)(tong)片(pian)(pian)(pian)填(tian)充(chong)在线电(dian)(dian)极加工(gong)(gong)形(xing)成的(de)(de)(de)缝隙里,并(bing)使铜(tong)(tong)片(pian)(pian)(pian)和缝隙壁紧密贴合。填(tian)充(chong)此(ci)铜(tong)(tong)片(pian)(pian)(pian)的(de)(de)(de)目的(de)(de)(de)是(shi)(shi)(shi)为了(le)导(dao)电(dian)(dian),因为前(qian)面粘贴连接铜(tong)(tong)片(pian)(pian)(pian)时(shi)用(yong)(yong)了(le)502胶(jiao)水(shui),而502胶(jiao)水(shui)是(shi)(shi)(shi)不(bu)导(dao)电(dian)(dian)的(de)(de)(de)。为了(le)实现导(dao)电(dian)(dian)要求,故采(cai)用(yong)(yong)填(tian)充(chong)导(dao)电(dian)(dian)铜(tong)(tong)片(pian)(pian)(pian)的(de)(de)(de)方法(fa),填(tian)充(chong)导(dao)电(dian)(dian)铜(tong)(tong)片(pian)(pian)(pian)时(shi)同样应注意(yi)铜(tong)(tong)片(pian)(pian)(pian)的(de)(de)(de)对称布置(zhi)以及铜(tong)(tong)片(pian)(pian)(pian)应同时(shi)加紧,并(bing)且(qie)(qie)不(bu)能塞得过紧以免划伤(shang)工(gong)(gong)件(jian)的(de)(de)(de)表(biao)(biao)面。不(bu)管是(shi)(shi)(shi)粘贴连接铜(tong)(tong)片(pian)(pian)(pian)还(hai)是(shi)(shi)(shi)填(tian)充(chong)导(dao)电(dian)(dian)铜(tong)(tong)缝隙的(de)(de)(de)形(xing)状(zhuang)。都应该把小铜(tong)(tong)片(pian)(pian)(pian)制成圆弧形(xing),而且(qie)(qie)还(hai)应该用(yong)(yong)金相(xiang)砂布打磨被锤过的(de)(de)(de)铜(tong)(tong)片(pian)(pian)(pian)表(biao)(biao)面,以保证铜(tong)(tong)片(pian)(pian)(pian)表(biao)(biao)面光滑(hua)以避免划伤(shang)工(gong)(gong)件(jian)已加工(gong)(gong)过的(de)(de)(de)表(biao)(biao)面。

在采用电火花线切(qie)割(ge)机加(jia)工(gong)(gong)(gong)高(gao)硬度、高(gao)精度和(he)(he)(he)高(gao)复杂度的(de)(de)小型(xing)工(gong)(gong)(gong)件(jian)时,按照上述方法和(he)(he)(he)步骤(zhou)(zhou)进行(xing)线切(qie)割(ge)加(jia)工(gong)(gong)(gong)中工(gong)(gong)(gong)件(jian)余留部(bu)位的(de)(de)精密(mi)(mi)切(qie)割(ge),是一种行(xing)之(zhi)有效的(de)(de)方法,它所提出的(de)(de)步骤(zhou)(zhou)和(he)(he)(he)技(ji)巧,经济简便(bian)、实(shi)用可行(xing),从而为改善和(he)(he)(he)提高(gao)精密(mi)(mi)线切(qie)割(ge)加(jia)工(gong)(gong)(gong)的(de)(de)质量和(he)(he)(he)效率探索(suo)出新的(de)(de)途径。


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