基于凝胶注模技术制备TiN-Cu电火花电极可行性研究
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摘要
本文主要探索凝胶注模技术制备TiN-Cu电火花加工用(EDM)电极的可行性。本文以TiN粉末和Cu粉末作为原料、海藻酸钠作为分散剂、明胶作为粘结剂,经过浆料制备、干燥、烧结成EDM电极。研究了pH值、分散剂、粘结剂对浆料流动性的影响和TiN-Cu EDM电极电加工性能。试验结果表明:当pH值为7、海藻酸钠质量分数为1%、明胶质量分数为1%时,30%TiN-Cu EDM电极相对损耗率为11.625%,比商用紫铜电极相对损耗率低,从而得出凝胶注模技术制备TiN-Cu EDM电极是可行的。
Herein,we reported the novel TiN-Cu electrical discharge machining electrode fabricated by gel injection molding.The gel comprised mixture of TiN-Cu powders,sodium-alginate dispersant and gelatin binder.The influence of the gel properties on the surface microstructures and relative loss-rate of the newly-developed EDM electrode was investigated with scanning electron microscopy to optimize the fabrication conditions.The results show that it is feasible to produce TiN-Cu EDM electrode by gel molding.To be specific,the TiN-Cu EDM electrode,fabricated by gel molding under the optimized conditions:30%(wt.) TiN-Cu,PH-value of 7,1% sodium-alginate and 1% gelatin,outperforms the commercial red-copper electrode because of lower relative loss-rate of 11.625%,faster machining speed,lower evaporate rate and higher melting point.The problems of low fracture toughness and high micro-defects density on EDM electrode surface,including pores,pits,and cracks,remain to be solved.
Herein,we reported the novel TiN-Cu electrical discharge machining electrode fabricated by gel injection molding.The gel comprised mixture of TiN-Cu powders,sodium-alginate dispersant and gelatin binder.The influence of the gel properties on the surface microstructures and relative loss-rate of the newly-developed EDM electrode was investigated with scanning electron microscopy to optimize the fabrication conditions.The results show that it is feasible to produce TiN-Cu EDM electrode by gel molding.To be specific,the TiN-Cu EDM electrode,fabricated by gel molding under the optimized conditions:30%(wt.) TiN-Cu,PH-value of 7,1% sodium-alginate and 1% gelatin,outperforms the commercial red-copper electrode because of lower relative loss-rate of 11.625%,faster machining speed,lower evaporate rate and higher melting point.The problems of low fracture toughness and high micro-defects density on EDM electrode surface,including pores,pits,and cracks,remain to be solved.
引文
[1] Srivastava V,Pandey P M.Study of Ultrasonic Assisted Cryogenically Cooled EDM Process Using Sintered (Cu-TiC) Tooltip[J].Journal of Manufacturing Processes,2013,15(1):158-166
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[5] 胡富强,王振龙,赵万生,等.线电极放电磨削(WEDG)技术的研究与应用[J].哈尔滨工业大学学报,2003,35(10)
[6] 张晶晶,王磊,张孝冬.基于正交试验TiN-Cu电火花加工用电极材料制备[J].真空科学与技术学报,2016,36(12):1437-1440
[7] 王霏,江开勇.琼脂凝胶注模成形不锈钢粉末浆料与生坯的性能[J].华侨大学学报:自然科学版,2011,32(3):247-252
[8] 赵席鹏,江开勇,王霏.明胶凝胶注模成型不锈钢浆料的制备与生坯的性能[J].机械工程材料,2012,36(12):58-61
[9] 陈騑騢.材料物理性能[M].北京:机械工业出版社,2006:200-250
[10] Lauwers B,Kruth JP,Liu W,et al.Investigation of Material Removal Mechanisms in EDM of Composite Ceramic Materials[J].Journal of Materials Processing Technology,2004,149(1):347-352
[11] 于家珊.电火花加工理论基础[M].北京:国防工业出版社,2011:174-230
[2] Khanra AK,Sarkar BR,Bhattacharya B,et al.Performance of ZrB2-Cu Composite as an EDM Electrode[J].Journal of Materials Processing Technology,2007,183(1):122-126
[3] Jahan MP,Rahman M,Wong YS,et al.On-Machine Fabrication of High-Aspect-Ratio Micro-Electrodes and Application in Vibration-Assisted Micro-Electrodischarge Drilling of Tungsten Carbide[J].Proceedings of the Institution of Mechanical Engineers Part B-Journal of Engineering Manufacture,2010,224(B5):795-814
[4] Peng Zilong,Wang Zhenlong,Dong Yinghuai,et al.Development of a Reversible Machining Method for Fabrication of Microstructures by Using Micro-EDM[J].Journal of Materials Processing Technology,2010,210(1):129-136
[5] 胡富强,王振龙,赵万生,等.线电极放电磨削(WEDG)技术的研究与应用[J].哈尔滨工业大学学报,2003,35(10)
[6] 张晶晶,王磊,张孝冬.基于正交试验TiN-Cu电火花加工用电极材料制备[J].真空科学与技术学报,2016,36(12):1437-1440
[7] 王霏,江开勇.琼脂凝胶注模成形不锈钢粉末浆料与生坯的性能[J].华侨大学学报:自然科学版,2011,32(3):247-252
[8] 赵席鹏,江开勇,王霏.明胶凝胶注模成型不锈钢浆料的制备与生坯的性能[J].机械工程材料,2012,36(12):58-61
[9] 陈騑騢.材料物理性能[M].北京:机械工业出版社,2006:200-250
[10] Lauwers B,Kruth JP,Liu W,et al.Investigation of Material Removal Mechanisms in EDM of Composite Ceramic Materials[J].Journal of Materials Processing Technology,2004,149(1):347-352
[11] 于家珊.电火花加工理论基础[M].北京:国防工业出版社,2011:174-230