微细电解线切割加工模型分析与试验研究

微细电解线切割加工模型分析与试验研究

摘要：微细电解线切割加工是一种微细加工新方法。由于原理上阴极不会损耗，采用微米级直径的电极丝，可加工出微米至数十微米尺度的复杂微结构件。基于电化学原理，讨论了微细电解线切割加工的机理，建立了加工的理论模型，得出了微米尺度线电极进给速度的理论上限。通过电解线切割加工试验，分析了各种加工参数对加工精度的影响规律，并加工出缝宽为20µm左右的微型桨叶结构。试验结果表明，微细电解线切割加工技术能为特殊性能材料的微细加工提供有效的新途径。

关键词：微细电解线切割加工；线电极；理论模型；试验研究

THEORETICAL MODEL AND EXPERIMENTS OF WIRE
ELECTROCHEMICAL MICRO-MACHINING
WANG Kun1,   ZHU Di2
 (1. College of Mechanical Engineering, Tongji University, Shanghai 200092, China;
2. College of Mechanical and Electrical Engineering, Nanjing University of Aeronautics and Astronautics, Nanjing 210016, China)

Abstract: Wire electrochemical micro-machining (WEMM) is proposed as a new method of precision machining in this paper. Because of no electrode wear in this process the micrometer scale metal wire can be used as the wire electrode in WEMM, and the micrometer or tens micrometer structure can be fabricated. Base on the principle of electrochemical, the mechanism of wire electrochemical micro-machining is investigated, the theoretical model of the method is founded and the top limit of feed speed of the micron scale wire electrode is studied. Effects of process parameters on the machining accuracy in the electrochemical micro-machining have been studied theoretically and experimentally, and micro blades with the slit width of 20µm is machined. It is proved experimentally that WEMM can provide a new effective manufacturing method for machining high-performance materials.
Key words: wire electrochemical micro-machining; Wire electrode; Theoretical model；Experimental research