吉 田 国枝:気 中放電加工 における工具電極微 消耗のメカニズ ム (a) Measurement of removed depth of copper and attached thickness of steel layer F'lg.3 Measurement results of chan
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1 Study on Mechanism for Minute Tool Electrode Wear in Dry EDM Masahiro YOSHIDA and Masanon KUNIEDA This paper clarifies the reasons for the minute tool electrode wear in the dry EDM. In the dry EDM, which has been newly developed, a high velocity gas flow supplied through a thin-walled pipe electrode removes and flushes the molten workpiece material out of the working gap without allowing it to reattach to the electrode surfaces. The greatest advantage of this technique is that the tool electrode wear is almost negligible for any pulse duration. It is thought that the attached molten workpiece material protects the tool electrode surface against wear. That is, the molten workpiece that has a higher melting point than that of the tool electrode adheres to the surface of the tool electrode that has a higher thermal conductivity than the workpiece. To verify this idea, the influence of the layer thickness of the workpiece material precipitated on the tool electrode surface on the temperature distribution in the tool electrode was numerically analyzed Then the tool electrode wear was simulated based on the result of the above heat conduction analysis. From observation of the cross section of the tool electrode surface, it was found that the tool electrode wore by the depth of only 2 Đm during the early stage of successive pulse discharges since the initial surface of the tool electrode was not covered with the steel layer. As the thickness of the steel layer increases, however, the wear of the base metal of the tool electrode ceases in one minute and thereafter the layer thickness is kept constant at 8.5 u m. These experimental results coincide well with the simulation results. Key words: dry EDM, tool electrode wear, heat conduction analysis, temperature distribution Fig. l Experimental setup to measure removal depth of tool electrode and attached thickness of workpiece material
2 吉 田 国枝:気 中放電加工 における工具電極微 消耗のメカニズ ム (a) Measurement of removed depth of copper and attached thickness of steel layer F'lg.3 Measurement results of change of tool electrode and attached layer with time in removed depth thickness of steel 3.工 作物付 着が工具電極内温度 分布 に及ぼす影響の解析 3.1解 析モデル 解 析モデル として温度伝導率 の良好 な銅工 具電極 加工面に工 具電極よ りも温度伝導率 は低 いが融点が高 い鋼 工作物が均一 に 付着 したモデル を考 え,鋼 付 着厚 さが 工具電 極内の温度分布 に (b) Photo of steel layer attached on EDMed surface 与 える影響 につ いて解析 を行 った.あ らか じめ任意の厚 さに工 作物 を付着 させ た工具 電極加工面 に単発放電 を生 じさせ,放 電 によって工 具電極 に流入する熱流 束による工具電極内の温度分 Fig.2 電極の組合せで加 工時 間を変 えて実験 を行 い,銅 工具電極 に付 着す る工作物付着 厚さ(以 下,鋼 付 着厚 さ)と 工具電極母材 の 除去深 さ(以 下,銅 部 除去深 さ)の 時間変化 を求めた.な お, 工具電極 と工作物 の位 置関係 は通常 の放電加工の場合 と逆 であ る.銅 工 具電極 加工面 には鋼付着 厚 さと銅部除去深 さを測定 す る基準面 が必要なため,あ らか じめ ラッピングを施 した工具電 極 の中央 部分で加工 を行 い両端 に基準面 を残す よ うに した.極 性 は気中加工で無消耗加工が 実現す る正極性で ある.そ の他の 加工条件を表1に 示す.な お,加 工の安定 のため工作物 に半径 0,5mmの 揺動を付加 している.図2(a)に 鋼 付着厚 さと銅部除去 深 さの測定方法 を示す.加 工後の工具電極 を図で示すよ うに側 面に平行 に1mm内 側の面で切断 し,切 断面にラ ッピングを施 し てエ ッジ部分のだれ を極 力な くして から断面観 察 を行 った.図 布 を非定常熱 伝導解析 によ って求 める.こ れ を付着厚 さを変 化 させて行 い工具電極 に付着 する鋼付着厚 さが工具電極内の温度 分布 に及 ぼす影響 を調 べた.本 研究 では図4に 示す ような時間 とともに直径d(t)の 変化す る円板状の均一熱源を上面中心 に持 つ,直 径D,長 さLの 円柱形の工具電極 モデルを用 い,軸 対称 2次 元問題 として差分法による解 析を行 った.計 算領域 として, 半径(D/2)を900μm,長 さLを630μmと し,こ れ を45 90の メッシュに分割 した.半径方向 のメッシュの大きさにつ いては, 中心 か ら30メ ッシュまでは5μm,そ れ以降 は50μmと した. また,軸 方向に関 しては,加工 面か ら60メ ッシュまでは0.5μ m,それ以降 は20μmで ある.気 化熱,融 解熱の考 慮は したが, 温度 伝導率等の物性値 の温度依 存性 は考慮せ ず室温での値 とし た. 2(a)中 に示す ように,銅 部除去深 さは基準面か ら除去された深 さとし,鋼 付着厚 さについて は工具電極 母材の銅 と付着層 との 境界か ら付着層 の表面 までの厚 さと定義す る.図2(b)に ラッピ ング処理後撮影 した断面写真 を示 す.鋼 の付着が はっき りと観 察 できる ことが 分かる.図3に 実験 によ って得 られた鋼 付着厚 さ と銅部 除去深 さの時間変化 の測 定結果 を示す.こ れか ら工具 電極母材の銅部 は放電加工開始直後 に約2μm除 去されるが,そ の後はほとん ど除去されず,鋼 付着厚 さは加工直後か ら急増 し, 1分 以内 に8.5μm程 度でほぼ一定 になる ことが分かる. Tlible 1 Machining conditions Fig.4 690精 密 工 学 会 誌Vol.65,No.5,1999 Model for computation of tool electrode temperature
3 Table 2 Thermophysical properties used in computation Fig.6 Influence of attached steel layer thickness on change in molten depth at discharge crater with increase of Fig.5 Measured change in radius of discharge crater pulse duration
4 Fig.7 Simulation procedure for tool electrode wear
5 2) B. N. Zolotykh: The Mechanism of Electrical Erosion of Metals in Liquid Dielectric Media, Soviet Phys., Tech.Phys., 4, 12 (1959) ) M. Kunieda, M. Yoshida: Electrical Discharge Machining in Gas, Ann. CIRP, 46,1 (1997) ) H. Xia, M. Kunieda and N. Nishiwaki: Removal Amount Difference between Anode and Cathode in EDM Process, UEM,1(1996) 45. 6) S. Hayakawa, M. Yuzawa, M. Kunieda and N. Nishiwaki: Mechanism of Determining the Power Distribution in Electrodes in EDM Process, ICPE'97 Taipei. Taiwan (1997) ) N. Mohri, M. Suzuki and N. Saito: Time Dependence of Electrode Wear in EDM. ISEM 11 (1995) ) A. S. Zingerman: The Effect of Thermal Conductivity upon the Electrical Erosion of Metals, Soviet Phys., Tech. Phys., (1956) ) H. Xia, M. Kunieda, N. Nishiwaki and N. Lior: Measurement of Energy Distribution into Electrodes in EDM Processes, JSPE Publication Series No.1, Advancement of Intelligent Production, Fig.8 Simulation results of change in removed depth of tool electrode and attached thickness of steel layer with time Elsevier Science B.V., (1994) 601.
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