Shallow the application in talking about black lead electrode to be machined in the mould

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The article introduced character of material of black lead electrode and treatment characteristic incisively, and in order to hang injection mould of machine face plate fixed die electrode of core black lead is a treatment method that elaborated electrode of common black lead in detail and process designing point, undertake through using black lead electrode to replace cupreous electrode the mould is made, shortened greatly the production of the mould is periodic, raised labor to manufacture efficiency, reduced the production cost of the mould. Reach efficient mould as exact pattern in recent years (mould cycle is shorter and shorter) roll out, the demand that people makes to the mould is higher and higher, as a result of cupreous electrode oneself the limitation of a variety of conditions, the development that already cannot satisfy mould industry more and more asks. Black lead regards EDM electrode as material, with its tall cutting sex, weight light, figuration is fast, expand small, nap allows rate minimum, loss to wait for an advantage easily, already got applied extensively in mould industry, replace cupreous electrode to already was become inevitable. One, material of black lead electrode is characteristic 1.

CNC machines speed tall, nap allows sex of fast, cutting rate of treatment of machine of easy black lead is rapid, the 3 ~ of the electrode that it is copper 5 times, finish machining speed is highlighted especially, and its intensity is very high, to freeboard (50 ~ 90mm) , ultrathin (0.

2 ~ 0.

5mm) electrode, add man-hour to be out of shape not easily. And in a lot of moment, the product needs to have very good grain side effect, when this is making electrode with respect to the requirement as far as possible fair electrode of make it whole, and horn of a variety of recessive Qing Dynasty exist when integral fair electrode is made, as a result of the character of the easy nap of black lead, make this one difficult problem very easy get settlement, and reduced the amount of electrode greatly, and cupreous electrode cannot be accomplished however. 2.

Fast EDM figuration, heat expands small, loss is small better than copper as a result of the conductivity of black lead, its discharge rate is so rapidder than copper, the 3~5 that is copper times. And bigger electric current can bear when its discharge, when electric spark rough machining more advantageous. In the meantime, below coequal bulk, the 1/5 that black lead weight is copper times, reduce the negative charge of EDM greatly. Large to making electrode, whole fair electrode has an advantage extremely. The sublimate temperature of black lead is 4200 ℃ , the 3~4 that is copper times (sublimate temperature of copper is 1100 ℃ ) . Below high temperature, be out of shape dinky (the 1/3~1/5 that copper is below coequal and electric condition) , not bate. Ground of OK and efficient, low cost conveys discharge energy to go up to workpiece. Because black lead issues intensity to increase instead in high temperature, reduce discharge loss effectively (the 1/4 that black lead loss is copper) , assured to machine quality. 3.

Weight light, cost is low in the making cost of a mould, the CNC machine of electrode the loss of time of handling time, EDM, electrode majority that holds total cost, and these are by electrode material itself place is decided. Black lead and cupreous photograph are compared, the 3 ~ that the machine treatment speed of black lead and EDM speed are copper 5 times. In the meantime, wear away of electrode of public black lead of dinky character and whole make, can reduce the amount of electrode, the bad news ability that also reduced electrode and machine handling time. All these, can reduce the making cost of the mould greatly. 2, requirement of treatment of Electromechanical of black lead electrode and characteristic 1.

Electrode makes the black lead of the making major of electrode basically use high speed machine tool to machine, machine tool stability is close friends, 3 axes motion should be stabilized equably not oscillatory, and like main shaft these circumgyrate precision also want as far as possible good. Also can complete the treatment of electrode to common machine tool, the craft that just writes cutter track and cupreous electrode differ somewhat. 2.

Electrode of black lead of EDM discharge treatment is carbolic electrode. Because the electric performance of black lead is good, can save a large number of time in discharge treatment so, this also is one of matters that become electrode with black lead. 3.

The treatment characteristic of black lead electrode is industrial black lead is qualitative hard and fragile, right when C N C is machined of cutting tool wear away relatively serious, general proposal uses the cutting tool of hard alloy or diamond coating. Black lead can fluctuate in workpiece directly in the cutting tool when rough machining knife, the happening of horn, disintegrate dies to avoid when finish machining, often use the means treatment that light knife takes quickly. Generally speaking, black lead is being cut deep be less than 0.

The circumstance of 2mm falls to produce collapse to break rarely, still can acquire better sidewall surface quality. The dirt of the generation when CNC of black lead electrode is machined is older, the likelihood inbreaks to wait to the slideway silk lever of the machine tool and main shaft, this machines a machine tool to have the corresponding unit that handles black lead dirt with respect to requirement black lead, machine tool sealing also is close friends, because black lead is poisonous. 3, those who if the graph is shown 1 times,machine example of black lead electrode is to hang injection mould of machine face plate fixed die electrode of core black lead, dimension of its semifinished product is 65mm of × of 182mm × 42mm, the biggest width is intermediate small chamfer 3.

1mm, the biggest chamfer deeply 5.

1mm, integral treatment is 64mm highly. The over all dimension of this sort electrode is medium, form is relatively complex, more general model is in black lead electrode. Whole model uses the Wildfire2 of Pro/ENGINEER.

0 undertake CNC Machining, nevertheless, preexistence kerosene is medium before be being machined immerse several hours, reduce its brittleness. Because intermediate chamfer is small and irregular, the treatment strategy of CAM is: First appearance of rough machining whole, again curved surface of finish machining figuration and lower end are linked together curved surface, catch rough machining intermediate small chamfer, among final precision work small chamfer. Graph 1 hang injection mould of machine face plate fixed die electrode of core black lead 1.

Integral rough machining uses D 2 0 (R 1) coating sets a milling cutter, use helix treatment means (T Y P E _ S P I R A L) , cut deep (S T E P _ D E P T H) 0.

3 5 M M, step pitch (S I D E _ S T E P) 8 M M, outline surplus (PROF_STOCK_ALLOW) 0.

35mm, rough machining surplus (ROUGH_STOCK_ALLOW) 0.

35mm, bottom surplus (BTTOM_STOCK_A L L O W) 0.

3 5 M M, machine means (ROUGH_OPTION) ROUGH_ONLY, safe height (CLEAR_DIST) 5mm, main shaft rotate speed (SPINDLE_SPEED) 2500r/min, feed speed (CUT_FEED)800mm/min. Use screen demonstrates (Screen Play) function, if the graph is shown 2 times,machine cutting tool contrail. In the meantime, undertake to treatment imitate is checked emulation (NC Check) had mixed cut an examination (GougeCheck) . Milling cutter did not enter the interior of intermediate chamfer, whole electrode appearance is given by mill, accord with the requirement of craft. By the alignment that finish (DoneS W Q) exit. Program calculative time is 50s, handling time is 2.

1h. Graph appearance of whole of 2 rough machining 2.

One finish machining chooses precision work D 1 6 (R 8) ball head milling cutter, use curved surface milling (the treatment means of SurfaceMilling) , step pitch (SIDE_STEP)0.

2mm, outline surplus (PROF_STOCK_ALLOW) - 0.

25mm, cutting angle (CUT_ANGLE) 45 ° , process a type (SCAN_TYPE) TYPE_3, safe height (CLEAR_DIST) 5mm, main shaft rotate speed (SPINDLE_SPEED) 2500r/min, feed speed (CUT_FEED)650mm/min. Use screen demonstrates (Screen Play) function, if the graph is shown 3 times,machine cutting tool contrail. In the meantime, undertake to treatment imitate is checked emulation (NC Check) and cut an examination too (Gouge Check) . Milling cutter did not enter the interior of intermediate chamfer, groove is exterior the negative surplus of curved surface be shapinged by the treatment of the definition (scintilla clearance is measured joltily namely) be gone to besides, accord with the requirement of craft. By the alignment that finish (Done Swq) exit. Program calculative time is 130s, handling time is 1.

5h. Graph 3 finish machining shape curved surface 3.

Finish machining 2 use D 2 0 (R 1) coating sets a milling cutter, process a type (SCAN_TYPE) TYPE_2, cut deep (STEP_DEPTH)0.

35mm, step pitch (SIDE_STEP)8mm, outline surplus (PROF_STOCK_ALLOW) - 0.

25mm, rough machining surplus (ROUGH_STOCK_ALLOW) 0.

35mm, bottom surplus (BTTOM_STOCK_ALLOW) 0mm, machine means (ROUGH_OPTION) PROF_ONLY, safe height (CLEAR_DIST) 5mm, main shaft rotate speed (SPINDLE_SPEED) 2500r/min, feed speed (CUT_FEED)800mm/min. Use screen demonstrates (Screen Play) function, if the graph is shown 4 times,machine cutting tool contrail. In the meantime, undertake to treatment imitate is checked emulation (NC Check) had mixed cut an examination (Gouge Check) . Milling cutter undertakes flank is machined, electrode lateral is reached the designated position by mill, accord with the requirement of craft. By the alignment that finish (Done Swq) exit. Program calculative time is 45s, handling time is 2h. Graph flank of 4 finish machining 4.

Small chamfer uses D 2 among rough machining (R 0.

4) milling cutter of coating ox bazoo, use helix to machine means (TYPE_SPIRAL) , cut deep (STEP_D E P T H) 0.

2 5 M M, step pitch (S I D E _STEP)0.

8mm, outline surplus (PROF_STOCK_ALLOW) - 0.

25mm, rough machining surplus (ROUGH_STOCK_ALLOW) - 0.

25mm, bottom surplus (BTTOM_STOCK_A L L O W) - 0.

3 5 M M, machine means (ROUGH_OPTION) ROUGH_ONLY, safe height (CLEAR_DIST) 5mm, main shaft rotate speed (SPINDLE_SPEED) 3500r/min, feed speed (CUT_FEED)450mm/min. Use screen demonstrates (Screen Play) function, if the graph is shown 5 times,machine cutting tool contrail. In the meantime, undertake to treatment imitate is checked emulation (NC Check) had mixed cut an examination (GougeC H E C K) . Milling cutter enters the interior of intermediate chamfer, groovy appearance is given by mill, accord with the requirement of craft. By the alignment that finish (Done Swq) exit. Program calculative time is 30s, handling time is 1h. Graph among 5 rough machining small chamfer 5.

3 finish machining choose precision work D 1 (R 0.

5) ball head milling cutter, use curved surface milling (the treatment means of SurfaceMilling) , step pitch (SIDE_STEP)0.

2mm, outline surplus (PROF_STOCK_ALLOW) - 0.

25mm, cutting angle (CUT_ANGLE) 45 ° , process a type (SCAN_TYPE) TYPE_3, safe height (CLEAR_DIST) 5mm, main shaft rotate speed (SPINDLE_SPEED) 3500r/min, feed speed (CUT_FEED)400mm/min. Use screen demonstrates (Screen Play) function, if the graph is shown 6 times,machine cutting tool contrail. In the meantime, undertake to treatment imitate is checked emulation (NC Check) had mixed cut an examination (Gouge Check) . Milling cutter enters the interior of intermediate chamfer, the machines figuration curved surface negative surplus that groovy interior is defined (scintilla clearance is measured joltily namely) be gone to besides, accord with the requirement of craft. By the alignment that finish (DoneS W Q) exit. Program calculative time is 60s, handling time is 0.

5h. Graph among 6 finish machining small chamfer 4, instructor of exercise of CNC Machining of instructor of editor treatment exercise is shown 7 times like the graph. Graph example of instructor of 7 treatment exercise 5, the development trend that the last word is aimed at prospective mould industry, who can be made in what the mould finishs in the shortest time, who won a client, gained the market. As a result of black lead electrode (compare with cupreous photograph) electrode uses up little, discharge to machine speed function of fast, machining good, weight is light, hot coefficient of expansion is small wait for advantage, had been known stage by stage by everybody and accept. Had black lead electrode to have a pattern tomorrow! CNC Milling CNC Machining