Electro-discharge ultra-fine drilling with carbon fiber electrodes

碳纤维电极放电超细钻孔

• 批准号: 429769676
• 负责人: Professor Dr.-Ing. Eckart Uhlmann
• 金额: --
• 依托单位: Fachgebiet Werkzeugmaschinen und Fertigungstechnik
• 依托单位国家: 德国
• 项目类别: Research Grants
• 财政年份: 2020
• 资助国家: 德国
• 起止时间: 2019-12-31 至 2022-12-31
• 项目状态: 已结题
• 来源: https://gepris.dfg.de/gepris/projekt/429769676?language=en
• 关键词: Electro; discharge; ultra; fine; drilling

The current machining limits of electrical discharge drilling are a hole diameter of Dmin = 6.5 micrometer and an aspect ratio of l/D = 7.5 . Challenges of drilling by electrical discharge machining with small diameters D consist of the manufacturing guiding of the tool electrode. In the case of drill holes with diameters D <= 50 micrometer conventional rod-electrodes cannot be used with the result that the necessary rod-electrodes need to be prepared by electrical discharge dressing which in turn leads to a considerable increase of manufacturing costs.Compared to conventional electrodes the main advantages of carbon fibres as tool electrodes regarding the manufacturing of drill holes with diameters D in the range of a few micrometers are the small diameters D, the good electrical conductivity K, as well as the low costs. However, the use of single carbon fibres as tool electrodes for precision drilling by electrical discharge machining is not sufficiently investigated.Goal of this research project is the investigation, development, and the provision of manufacturing technologies as well as machining strategies for drilling of cylindrical holes with diameters of 10 micrometer <= D <= 30 micrometer and aspect ratios of l/D >= 10 by electrical discharge drilling with carbon fibre tool electrodes. Since no knowledge about the material-related removal process exists a technological research in dependence to generator parameters and dielectrics is necessary. In addition, the investigation of the fundamental relationships of process parameters, the maximum achievable aspect ratio l/D, the minimum achievable manufacturing tolerance, the maximum achievable removal rate Vw, and the reproducibility will be in the main focus of the research.After completion of the research project fundamental knowledge about the material-related removal process and interactions between tool and workpiece as well as technologies for the precision drilling of single holes by electrical discharge drilling with carbon fibre electrodes will be available. The technology that is to be developed in the scope of this project can be used for manufacturing of components like membranes, spinnerets, air bearings, and micro-feeders and can help to reduce manufacturing time and costs.

目前放电钻孔的加工极限是孔径 Dmin = 6.5 微米，长径比 l/D = 7.5。小直径 D 放电加工钻孔的挑战包括工具电极的制造引导。对于直径D≤50微米的钻孔，无法使用传统的棒电极，因此需要通过放电修整来制备必要的棒电极，这又导致制造成本的显着增加。与传统电极相比，碳纤维作为工具电极在制造直径D在几微米范围内的钻孔时的主要优点是直径D小、导电性K良好以及成本低。然而，使用单根碳纤维作为工具电极通过放电加工进行精密钻孔的研究还不够。该研究项目的目标是研究、开发和提供用于钻圆柱孔的制造技术和加工策略。使用碳纤维工具电极进行放电钻孔，直径为 10 微米 <= D <= 30 微米，纵横比 l/D >= 10。由于不存在与材料相关的去除过程的知识，因此有必要对发生器参数和电介质进行技术研究。此外，工艺参数的基本关系、最大可实现的长宽比l/D、最小可实现的制造公差、最大可实现的去除率Vw和再现性的研究将是研究的主要重点。完成后该研究项目将提供有关材料相关去除过程、工具和工件之间相互作用的基础知识，以及通过碳纤维电极放电钻孔进行单孔精密钻孔的技术。该项目范围内开发的技术可用于制造膜、喷丝板、空气轴承和微型进料器等组件，有助于减少制造时间和成本。