Special processing of molds

1 Wire EDM

Micro-EDM in EDM has been widely used. The emergence of WEDG technology has satisfactorily solved the problems of the production and installation of micro-electrodes, and has brought micro-EDM to the stage of application. In this regard, Takahisa Masuzawa of the University of Tokyo and others have machined a fine shaft of Φ2.5mm and a fine hole of Φ5mm, which represents the world's leading edge in this field. According to statistics, the proportion of micro-EDM and then EDM is increasing year by year, and is currently close to 10%.

New technology of slow-moving wire cutting continues to emerge

Slow walking wire cutting processing is the main development hotspot in recent years. With the development and application of electroless pulse power supply, optimized energy pulse power supply, ion control by deionized water, and a series of precision processing technologies, the development of slow wire cutting has reached a new stage. The slow-moving wire-cutting machine tool of Swiss AgieCharmilles can obtain contour accuracy of 1.5um and Ra0.1um processing quality, which is suitable for the processing of precision die. With the realization of localization, the price of this type of machine tool is rapidly decreasing and gradually widely used.

Agie company developed the AgiecutVertex double wire EDM machine tool. The machine has two reels, which can use different diameter wires to cut at the same time to improve cutting efficiency. All operations are completed automatically, and there are sensors to monitor its operation. The diameter of the cut wire is 0.02-0.02mm.

2 EDM technology is developing towards high precision and high automation

In recent years, CNC EDM technology can use standard copper tube electrodes and CAD/CAM technology to complete two-dimensional or three-dimensional surface processing. It does not need to make shaped electrodes, which greatly simplifies the preparation of electrodes. On the one hand, it has good prospects.

Recently, Japan has invented a new EDM processing method, that is, adding an appropriate amount of fine silicon powder, or aluminum powder or graphite powder, to the processing fluid, which can increase the surface accuracy by several times. At present, the EDM machine tool corresponding to this processing method has also been commercialized. In the future, EDM technology is inseparable from three trends, namely, high-speed, high-precision and high-automation.

3Machinery special processing

It can be divided into a variety of processing methods such as abrasive flow processing, water jet processing, low-stress grinding, and ultrasonic processing.

Abrasive water jet processing can be competent for precision cutting, processing workpieces without burrs, and another advantage of water jet processing is that it can touch places that are not easily accessible by other tools.

Ultrasonic special processing uses tools to produce vibration amplitude. Through transmission, liquid abrasive particles gain the ability to hit the workpiece to realize processing. This technology is not widely used, and is mainly used in the ultrasonic polishing of molds. Research on ultrasonic abrasive processing is being carried out abroad. In particular, the research on rotary ultrasonic has significantly improved the quality of deep hole drilling. For many years, the United States has been conducting research on ultrasonic-assisted diamond tool processing, and Japan is also developing ultrasonic-assisted grinding.

4Other thermal special processing

Other thermal special processing refers to the use of electron beams, laser beams, and plasma beams to generate heat to ablate metal to achieve the purpose of processing. There are mainly processing methods such as electron beam, electric discharge grinding, laser processing, and plasma beam processing.

The electron beam processing technology has developed rapidly in the past 20 years. The electron beam has been able to enter the processing of micro, welding, coating, smelting, heat treatment, exposure, radiation and so on. Electron beam processing technology will develop in the direction of high power, high precision, miniaturization and automation.

Ion beam processing can be used for milling, sputtering coating, ion plating and micro processing, etc. In particular, IAC technology has the advantages of both vapor deposition and ion implantation, and can produce strong adhesion and compact structure. Various functional coatings with excellent performance. The plasma arc assisted cutting process can change the physical and mechanical properties of the local materials of metal materials and superalloy materials with a hardness of 40-70HRC.