微細線材自動進級超微細孔放電加工技術研發

Development of Automatic Electrode Feeding System of Microholes Machining by Micro-EDM

楊明達(Ming-Da Yang)

指導教授 ： 許東亞

國立臺北科技大學/機電學院/製造科技研究所/碩士(2006年)

https://doi.org/10.6841/NTUT.2006.00288

摘要

微放電加工是品質優良且設備成本低廉的微細孔加工技術，但微放電加工尚有許多問題使微細孔加工無法量化。
傳統使用WEDG技術加工微細工具電極，可加工出超微細的工具電極，但製作過程緩慢，無法提供微細孔量產使用，因此本研究提出以鑽石砂輪研磨微細工具的方式，快速生產微細工具，將微細工具裝置於直柄式夾頭，成為微放電加工機的直柄式加工主軸。由實驗獲知，微細工具電極加工的入口孔徑為工具電極的直徑﹢20±5μm，高深徑比之微細孔加工適合使用具有排屑功能的微細鑽頭，可減少工具消耗長度，增快加工效率，低深徑比之微細孔適合使用微細棒材，可減少入出口差，實驗最後調查並統計微細工具電極的極限加工孔數，供微細孔加工參考使用。
鑽石砂輪研磨技術雖然可以解決工具電極製作緩慢的問題，但工具電極消耗後，仍需重新安裝，使生產無法自動化，因此本研究使用自行設計的微細線材自動進級裝置，以自動鉛筆機構的方式，進行微細線材的自動進級，配合WEDG技術切除角隅消的微細線材，達到微細孔生產自動化的目的。使用自動進級主軸夾持φ100μm微細鎢線材於厚度100μm之SUS 304薄板連續加工100孔，入口孔徑可保持在115~125μm以內，入出口差最大為15μm，真圓度1μm，微細孔加工程序於單一加工機完成，成為真正具有微細孔量產能力的微放電加工機。

關鍵字

微細放電加工 ； 線放電研磨 ； 生產自動化

並列摘要

This research mainly used the mechanism of automatic microelectrode feeding system to achieve mass production of microholes by EDM. This dissertation proposed two kinds of spindle mechanism, cylindrical shaft holder spindle and automatic microelectrode feeding system respectively, that can chuck micro electrode of diameterψ100um to manufacture microholes by EDM. Cylindrical shaft holder spindle mounted on V-shaped, can hold a micro rod tool fabricated by diamond grind, to machine micro holes directly by EDM. Automatic microelectrode feeding system, using mechanism of propelling pencil to hold tungsten micro rod electrode, that we don’t need to change micro electrode while micro tools were worn out.
Using cylindrical shaft holder spindle to fabricate micro holes by EDM, the experimental results show that the diameter of microholes inlet is the diameter of micro tool ﹢20±5μm. Micro driller is adaptable to machining of high aspect ratio hole, and micro wand is adaptable to machining of low aspect ratio hole. On the other hand, in automatic micro electrode feeding system continuous machining 100 microholes, the dimensions of micro holes are about 115-125 um in diameters. The differences between inlet and outlet are almost 15 um. The length of micro electrode wear is about 1000um. Micro holes could be machined continuous until the micro rod electrode is worn out.
The system is possible to achieve mass production of micro holes by EDM at low cost.

並列關鍵字

Micro-EDM ； WEDG ； Automatic production

參考文獻

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