Basic research concerning Electrical Discharge Machining with additive manufactured tool electrodes

使用增材制造工具电极进行放电加工的基础研究

• 批准号: 451468634
• 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/451468634?language=en
• 关键词: Basic; research; concerning; Electrical; Discharge

In process chains with EDM die-sinking the highest manufacturing efforts can be found in the production of tool electrodes. This effort multiplies with increasing tool electrode wear ϑ because of insufficient flushing. A higher amount of tool electrodes is required in order to compensate the tool electrode wear. The manufacturing method Selective Laser Melting (SLM) offers new opportunities in machining tool electrodes for EDM applications. Complex form electrode geometries with interior flushing channels can be realised with the manufacturing principles of additive manufacturing. The material properties of tungsten carbide are ideal for the application in EDM. Due to the high effort in machining tungsten carbide, the manufacturing of form electrodes out of tungsten carbide has been neglected so far. By the possibility to machine tungsten carbide by SLM, this material can be applied for form electrodes in EDM die-sinking besides the application in EDM drilling operations.The aim of this research project is the validation of additive manufactured tungsten carbide as tool electrode material for EDM. The variation of the SLM process parameters leads to differing cobalt content GCo and changing EDM process behaviour of the additive manufactured tool electrodes.Appropriate process parameters for rough machining of different materials with tungsten carbide tool electrodes shall be identified. The implementation of interior flushing channels causes further improvement of the processing results, especially when machining high aspect ratios A. The scientific analysis of the experimental results leads to extensive findings in the area of EDM. The acquired knowledge and the specific material characteristics of the carbide WC-Co allow the improvement of important process characteristics like material removal rate VW and electrode wear in EDM die-sinking. The results of this research project can be used for further scientific investigations like improving the SLM electrodes by further processing with different coatings. The additive manufactured electrodes could be applied for finishing and polishing processes. Another investigation can analyse the addition of alloying additives to WC-Co, such as vanadium carbide in order to improve the EDM process.

在采用 EDM 开模的工艺链中，最大的制造工作量是在工具电极的生产中，由于冲洗不足，需要更多的工具电极来补偿工具电极的磨损。选择性激光熔化 (SLM) 制造方法为 EDM 应用的加工工具电极提供了新的机会，可以通过增材制造的制造原理来实现具有内部冲洗通道的复杂形状电极。碳化钨是 EDM 应用的理想选择 由于加工碳化钨需要付出很大的努力，因此迄今为止，通过 SLM 加工碳化钨的可能性一直被忽视。除了应用于 EDM 钻孔操作外，还应用于 EDM 开模中的成形电极。该研究项目的目的是验证增材制造的碳化钨作为工具电极材料的有效性SLM 工艺参数的变化导致不同的钴含量 GCo 并改变增材制造工具电极的 EDM 工艺行为。应确定使用碳化钨工具电极粗加工不同材料的适当工艺参数。通道导致加工结果的进一步改善，特别是在加工高纵横比 A 时。对实验结果的科学分析导致​​了 EDM 领域的广泛发现。所获得的知识和特定材料特性。硬质合金 WC-Co 可以改善 EDM 开模中的材料去除率 VW 和电极磨损等重要工艺特性。该研究项目的结果可用于进一步的科学研究，例如通过使用不同涂层进行进一步加工来改进 SLM 电极。增材制造的电极可用于精加工和抛光工艺，另一项研究可以分析向 WC-Co 中添加合金添加剂，例如碳化钒，以改进 EDM 工艺。