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慢走絲線切割鉬絲的斷絲現象的原因

慢走絲線切割鉬絲斷絲的現象,除了與電極絲和工作液相關,與其他因素也有一些關系,比如,走絲的速度和精度、進給速度、工件的材質等等。因此,在進行線切割加工時,為了減少斷絲,不同的材質應選用相應的加工參數。下面鉬絲廠家就為大家介紹下:

1、走絲速度

線(xian)(xian)(xian)材運行的(de)(de)(de)速度(du)(du)(du)(du)直接影響線(xian)(xian)(xian)材電(dian)(dian)(dian)(dian)(dian)(dian)極(ji)在(zai)加(jia)工(gong)(gong)(gong)區的(de)(de)(de)停留時間(jian)和放(fang)電(dian)(dian)(dian)(dian)(dian)(dian)次數,從而影響線(xian)(xian)(xian)材電(dian)(dian)(dian)(dian)(dian)(dian)極(ji)的(de)(de)(de)損(sun)耗(hao)。由(you)于WEDM的(de)(de)(de)線(xian)(xian)(xian)電(dian)(dian)(dian)(dian)(dian)(dian)極(ji)直徑較小,如果線(xian)(xian)(xian)電(dian)(dian)(dian)(dian)(dian)(dian)極(ji)移(yi)動(dong)太慢(man),線(xian)(xian)(xian)電(dian)(dian)(dian)(dian)(dian)(dian)極(ji)上的(de)(de)(de)某(mou)一點可能會(hui)發生(sheng)多次放(fang)電(dian)(dian)(dian)(dian)(dian)(dian),使得該點的(de)(de)(de)腐蝕量過大,在(zai)電(dian)(dian)(dian)(dian)(dian)(dian)火花放(fang)電(dian)(dian)(dian)(dian)(dian)(dian)的(de)(de)(de)線(xian)(xian)(xian)張力和爆燃力的(de)(de)(de)作用下(xia),很容易斷線(xian)(xian)(xian)。另外,提高電(dian)(dian)(dian)(dian)(dian)(dian)熱絲(si)的(de)(de)(de)走絲(si)速度(du)(du)(du)(du),可以很容易地將(jiang)工(gong)(gong)(gong)作液帶(dai)到(dao)狹窄(zhai)的(de)(de)(de)加(jia)工(gong)(gong)(gong)間(jian)隙(xi),加(jia)強電(dian)(dian)(dian)(dian)(dian)(dian)極(ji)絲(si)的(de)(de)(de)冷卻,將(jiang)腐蝕產物(wu)帶(dai)出間(jian)隙(xi)。但(dan)如果走線(xian)(xian)(xian)速度(du)(du)(du)(du)過高,電(dian)(dian)(dian)(dian)(dian)(dian)極(ji)絲(si)的(de)(de)(de)振動(dong)會(hui)增大,容易斷絲(si),加(jia)工(gong)(gong)(gong)表面(mian)精度(du)(du)(du)(du)降低,表面(mian)粗糙度(du)(du)(du)(du)增大。因此(ci),在(zai)線(xian)(xian)(xian)電(dian)(dian)(dian)(dian)(dian)(dian)極(ji)允(yun)許少量連(lian)續(xu)放(fang)電(dian)(dian)(dian)(dian)(dian)(dian)次數的(de)(de)(de)情況(kuang)下(xia),應根(gen)據(ju)工(gong)(gong)(gong)件的(de)(de)(de)厚度(du)(du)(du)(du)和放(fang)電(dian)(dian)(dian)(dian)(dian)(dian)頻率正確(que)調(diao)整線(xian)(xian)(xian)速度(du)(du)(du)(du)。

2、進給速度

理想的線切割,應該是進給速度跟蹤其線加工速度。進給過快,超過工件可能的蝕除速度,容易造成頻繁短路,切割白鉬絲速度反而慢,工件表面粗糙度也較差,上、下端面切縫呈焦黃色,甚至可能斷絲;進給過慢,滯后于工件可能的蝕除速度,則容易造成頻繁開路,過跟蹤和欠跟蹤都是造成加工不穩定的直接因素,容易引起斷絲,影響表面加工質量。

慢走絲線切割鉬絲的斷絲現象的原因


3、進給精度

為了實現理想的跟蹤進給,需要提高進給控制系統的性能,并手動調整較好的進給速度。導絲機構的精度會直接影響電極絲的走絲質量,精度低會產生偏差和振動,進而造成斷絲。線切割機的(de)(de)導絲(si)機構主(zhu)要由儲絲(si)管、絲(si)夾(jia)和導輪(lun)組(zu)成(cheng)。當導絲(si)機構的(de)(de)精度降(jiang)低時(shi),會(hui)引起儲絲(si)筒的(de)(de)徑向跳動(dong)和軸向移動(dong)。徑向跳動(dong)會(hui)降(jiang)低線電(dian)極的(de)(de)張力,導致(zhi)(zhi)導線松動(dong),嚴重時(shi)會(hui)導致(zhi)(zhi)導線從導輪(lun)槽(cao)中脫出。軸向移動(dong)會(hui)導致(zhi)(zhi)導線排列不均(jun)勻,造成(cheng)導線重疊。如果(guo)線軸剛性(xing)差,移動(dong)時(shi)會(hui)產生振動(dong)和擺動(dong),不僅影響精度,還會(hui)造成(cheng)斷線。

4、電極絲的材料及(ji)直徑

電極絲的材料有銅、鎢、鉬和鎢鉬合金,其壽命(ming)比鉬(mu)絲(si)(si)(si)(si)提高(gao)20%-30%左右,斷絲(si)(si)(si)(si)現(xian)象明顯減少。由(you)于鎢鉬(mu)合金(jin)具有較高(gao)的延(yan)伸率、抗拉(la)力和熔點等性能(neng),為了減少斷絲(si)(si)(si)(si),選用(yong)鎢鉬(mu)合金(jin)電(dian)極絲(si)(si)(si)(si)。對(dui)慢走絲(si)(si)(si)(si),高(gao)生產率時(shi)可采(cai)用(yong)0.12~0.30毫米鍍鋅銅(tong)絲(si)(si)(si)(si),以允許更大的峰值(zhi)電(dian)流。若能(neng)保持電(dian)極絲(si)(si)(si)(si)張力均勻、振動小(xiao)、加工穩(wen)定(ding),則(ze)工件(jian)精度與(yu)表面(mian)粗糙度相當,電(dian)極絲(si)(si)(si)(si)壽命(ming)也較長。