多工位组合电极电火花成形微凹槽结构

发布时间：2019-03-22 20:08

【摘要】：针对具有复杂微尺度凹槽结构的高硬度模具钢型腔难以加工的难题,提出了一种多工位组合电极电火花成形的新方法。以某种聚合物微流控芯片模具型腔为研究对象,选用NAK80模具钢为型腔材料,铜钨合金(W75%)为相应的微凸起结构电极材料并经由高速铣削加工。为降低加工难度及保障加工质量,对复杂微凸起结构进行分解,形成2组4工位组合电极;采用周铣、端铣交替进行的工艺使微凸起上表面的毛刺连续发生塑性变形从而减小和去除微凸起结构顶端的加工毛刺。最后,利用制备好的多工位组合电极,采用变换工位代替更换电极的加工方式,通过精密电火花成形,依次完成粗、半精与精加工。结果表明:加工的凹槽侧壁与底面垂直度较好,宽度、高度误差在3μm以内,根部圆角在15μm以内,可以满足成型聚合物微流控芯片的使用要求。
[Abstract]:In view of the difficult problem of machining high hardness die steel cavity with complex micro-scale grooves, a new method of multi-position composite electrode EDM is presented in this paper. Taking a polymer microfluidic chip mould cavity as the research object, NAK80 die steel was selected as the cavity material and copper-tungsten alloy (W75%) as the corresponding micro-bulge structure electrode material, which was machined by high-speed milling. In order to reduce the machining difficulty and guarantee the machining quality, the complex micro-bulge structure is decomposed to form two groups of 4-position composite electrodes. The continuous plastic deformation of the burr on the upper surface of the micro-bulge is caused by alternating milling and end milling, so as to reduce and remove the machined burr at the top of the micro-bulge structure. Finally, by using the prepared multi-position composite electrode and replacing the replacement electrode by changing the working position, the coarse, semi-fine and refined machining is completed by precise EDM. The results show that the verticality between the side wall and the bottom of the grooves is better, the width, the height error is less than 3 渭 m, and the root fillet is less than 15 渭 m, which can meet the requirements of forming polymer microfluidic chips.
【作者单位】：大连理工大学精密与特种加工教育部重点实验室;三菱电机大连理工大学电加工技术中心;
【基金】：国家863高技术研究发展计划资助项目(No.2012AA040406) 中央高校基本科研业务费专项资金资助项目(No.DUT13JB05) 辽宁省自然科学基金资助项目(No.201202036)
【分类号】：TG661

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