阅读说明：本技术 线放电加工用电极线 (Electrode wire for wire electric discharge machining ) 是由 枣田善贵 岩本力俊 于 2018-03-01 设计创作，主要内容包括：一种线放电加工用电极线,其具有由钢构成的芯线部和覆盖所述芯线部的外周侧且由铜锌合金构成的包覆层。所述包覆层以包含所述线放电加工用电极线的表面的方式设置。所述包覆层由γ相单相构成。所述包覆层在周向上具有0.08μm以下的表面粗糙度Ra。所述包覆层在纵向上具有0.08μm以下的表面粗糙度Ra。(An electrode wire for wire electric discharge machining has a core wire portion made of steel and a cladding layer made of a copper-zinc alloy covering the outer peripheral side of the core wire portion. The coating layer is provided so as to include a surface of the wire electrode for wire electric discharge machining. The coating layer is composed of a gamma-phase single phase. The coating layer has a surface roughness Ra of 0.08 [ mu ] m or less in the circumferential direction. The coating layer has a surface roughness Ra of 0.08 μm or less in the longitudinal direction.)

1. An electrode wire for wire electric discharge machining, comprising:

a core wire portion made of steel; and

a coating layer made of a copper-zinc alloy covering an outer peripheral side of the core wire portion, the coating layer being provided so as to include a surface of the wire electric discharge machining electrode wire,

wherein the coating layer is composed of a gamma-phase single phase,

the coating layer has a surface roughness Ra of 0.08 μm or less in the circumferential direction, and

the coating layer has a surface roughness Ra of 0.08 μm or less in the longitudinal direction.

2. The electrode wire for wire electric discharge machining according to claim 1, wherein the clad layer has a surface roughness Rz of 0.50 μm or less in the longitudinal direction.

3. The electrode wire for wire electric discharge machining according to claim 1 or 2, wherein crystal grains in a surface layer region that is a region including a surface of the clad layer have a shape that is longer in a longitudinal direction of the electrode wire for wire electric discharge machining than in a radial direction.

4. The electrode wire for wire electric discharge machining according to claim 3, wherein a ratio of longitudinal length to radial length of crystal grains in the surface layer region is larger than a ratio of longitudinal length to radial length of crystal grains in an inner region located on an inner peripheral side of the surface layer region.

5. The electrode wire for wire electric discharge machining according to any one of claims 1 to 4, wherein an outer periphery of a cross section perpendicular to the longitudinal direction has a roundness of 0.25 μm or less.

6. The electrode wire for wire electric discharge machining according to any one of claims 1 to 5, wherein a surface of the electrode wire for wire electric discharge machining contains 10 or less cracks in a range of a length of 100 μm in a longitudinal direction of the electrode wire for wire electric discharge machining.

7. The electrode wire for wire electric discharge machining according to any one of claims 1 to 6, wherein the electrode wire for wire electric discharge machining has an electric conductivity of 8% IACS or more and 20% IACS or less.

8. The electrode wire for wire electric discharge machining according to any one of claims 1 to 7, wherein the electrode wire for wire electric discharge machining has a surface hardness of 300HV or more and 600HV or less.

9. The electrode wire for wire electric discharge machining according to any one of claims 1 to 8, wherein the copper-zinc alloy forming the clad layer has a zinc content of 60 mass% or more and 75 mass% or less.

Technical Field

The present invention relates to an electrode wire for wire electric discharge machining.

This application claims priority from japanese patent application 2017-097092, filed on 16.5.2017, the entire contents of which are incorporated herein by reference.

Background

In the wire electric discharge machining, a voltage is applied between a workpiece immersed in a liquid and an electrode wire, so that heat generated by electric discharge melts the workpiece, thereby machining the workpiece. There is known an electrode wire for wire electric discharge machining (electrode wire for wire electric discharge machining) having a core wire portion composed of steel and a clad layer formed on a surface thereof and composed of a copper-zinc alloy (Cu — Zn alloy) (see, for example, patent document 1).

Disclosure of Invention

An electrode wire for wire electric discharge machining according to the present disclosure includes a core wire portion made of steel and a clad layer made of a copper-zinc alloy covering an outer peripheral side of the core wire portion. The coating layer is provided so as to include a surface of the wire electrode for wire electric discharge machining. The coating layer is composed of a gamma-phase single phase. The coating layer has a surface roughness Ra of 0.08 [ mu ] m or less in the circumferential direction. The coating layer has a surface roughness Ra of 0.08 μm or less in the longitudinal direction.

Drawings

Fig. 1 is a schematic view showing the structure of an electrode line.

Fig. 2 is a schematic sectional view showing a cross section parallel to the longitudinal direction of an area near the surface of the electrode line.

Fig. 3 is a schematic sectional view showing a cross section perpendicular to the longitudinal direction of an area near the surface of the electrode line.

Fig. 4 is a flow chart summarizing a method for manufacturing an electrode line.

Fig. 5 is a schematic sectional view showing a cross section of a raw steel wire perpendicular to a longitudinal direction.

Fig. 6 is a schematic sectional view showing a drawing step, a Cu layer forming step, and a Zn layer forming step.

Fig. 7 is a schematic sectional view showing a first heat treatment step.

Fig. 8 is a schematic view showing the profile of a cross section perpendicular to the longitudinal direction after completion of the first heat treatment step.

Fig. 9 is a schematic view showing the profile of a cross section perpendicular to the longitudinal direction after a smooth drawing step with an area reduction rate of 1%.

Fig. 10 is a schematic view showing the profile of a cross section perpendicular to the longitudinal direction after a smooth drawing step with an area reduction rate of 4%.

Fig. 11 is a graph showing the relationship between the area reduction rate and the conductivity.

Detailed Description

[ problem to be solved by the present disclosure ]

In the wire electric discharge machining, high-speed machining is required from the viewpoint of improving productivity. In the wire electric discharge machining, there is also a need to improve the dimensional accuracy of the parts manufactured by machining, that is, to improve the machining accuracy. Accordingly, an object of the present invention is to provide an electrode wire for wire electric discharge machining, which is capable of achieving both high-speed machining and high machining accuracy.

[ advantageous effects of the present disclosure ]

The electrode wire for wire electric discharge machining can be used as an electrode wire for wire electric discharge machining that can achieve both high-speed machining and high machining accuracy.

[ description of embodiments of the invention ]

First, the embodiments of the present invention listed below will be explained. An electrode wire for wire electric discharge machining according to the present application includes a core wire portion made of steel and a clad layer made of a copper-zinc alloy covering an outer peripheral side of the core wire portion. The coating layer is provided so as to include a surface of the wire electrode for wire electric discharge machining. The coating layer is composed of a gamma-phase single phase.

The coating layer has a surface roughness Ra of 0.08 [ mu ] m or less in the circumferential direction. The coating layer has a surface roughness Ra of 0.08 μm or less in the longitudinal direction.

The coating layer of the electrode wire for wire electric discharge machining according to the present application is composed of a γ -phase-single-phase copper-zinc alloy. This enables high-speed processing. However, according to the studies conducted by the present inventors, the clad layer composed of the γ -phase single-phase copper-zinc alloy may have a large roughness in the circumferential direction, and thus the machining accuracy may be lowered. Since the clad layer of the electrode wire for wire electric discharge machining according to the present application has a surface roughness Ra of 0.08 μm or less in the circumferential direction, a decrease in machining accuracy is suppressed.

In addition, according to the studies conducted by the present inventors, the clad layer composed of the γ -phase single-phase copper-zinc alloy tends to exhibit cracks extending in the circumferential direction. These cracks may increase longitudinal roughness and may also decrease electrical conductivity. In addition, the clad layer composed of the γ -phase single-phase copper-zinc alloy may have large roughness in the longitudinal direction as well as in the circumferential direction, thereby possibly lowering the machining accuracy. Since the clad layer of the electrode wire for wire electric discharge machining according to the present application has a surface roughness Ra of 0.08 μm or less in the longitudinal direction, a decrease in electrical conductivity is suppressed, and a decrease in machining accuracy is also suppressed.

Therefore, the electrode wire for wire electric discharge machining according to the present application can achieve both high-speed machining and high machining accuracy.

In the electrode wire for wire electric discharge machining, the clad layer may have a surface roughness Rz of 0.50 μm or less in the longitudinal direction. This further suppresses a decrease in the electrical conductivity, and also further suppresses a decrease in the processing accuracy.

In the wire electric discharge machining electrode wire, the crystal grains in the surface layer region that is a region including the surface of the clad layer may have a shape that is longer in the longitudinal direction of the wire electric discharge machining electrode wire than in the radial direction. This reduces the surface roughness in the circumferential direction of the electrode wire. In addition, cracks extending in the circumferential direction of the electrode wire are suppressed, thereby reducing surface roughness in the longitudinal direction, and also making it easier to ensure sufficient electrical conductivity.

In the electrode wire for wire electric discharge machining, a ratio of a longitudinal length to a radial length of a crystal grain in the surface layer region may be larger than a ratio of a longitudinal length to a radial length of a crystal grain in an inner region located on an inner peripheral side of the surface layer region. This reduces the surface roughness in the circumferential direction of the electrode wire. In addition, cracks extending in the circumferential direction of the electrode wire are suppressed, thereby reducing surface roughness in the longitudinal direction, and also making it easier to ensure sufficient electrical conductivity.

In the electrode wire for wire electric discharge machining, an outer periphery of a cross section perpendicular to the longitudinal direction may have a roundness of 0.25 μm or less. This can further improve the machining accuracy.

In the wire electric discharge machining electrode wire, the surface of the wire electric discharge machining electrode wire may contain 10 or less cracks within a length of 100 μm in the longitudinal direction of the wire electric discharge machining electrode wire. This makes it easier to ensure sufficient conductivity.

The electrical conductivity of the electrode wire for wire electric discharge machining may be 8% IACS (international annealed copper standard) or more and 20% IACS or less. This allows the electrode wire for wire electric discharge machining to have appropriate electrical conductivity.

The wire electric discharge machining electrode wire may have a surface hardness of 300HV or more and 600HV or less. This gives the cladding sufficient strength.

The surface hardness can be measured, for example, by using a durometer (DUH-211) available from Shimadzu corporation.

In the electrode wire for wire electric discharge machining, the copper-zinc alloy forming the coating layer may have a zinc content of 60 mass% or more and 75 mass% or less. This makes it easier to obtain a clad layer consisting of a gamma-phase-single-phase copper-zinc alloy.

[ details of embodiments of the present invention ]

Next, embodiments of the electrode wire for wire electric discharge machining according to the present invention will be explained below with reference to the drawings. In the following drawings, the same or corresponding components are denoted by the same reference numerals, and the description thereof will not be repeated.

Referring to fig. 1, an electrode wire 1 as an electrode wire for wire electric discharge machining according to the present embodiment includes a core wire portion 10 made of steel and a coating layer 20 made of a copper-zinc alloy covering an outer peripheral side of the core wire portion 10. The cladding layer 20 is provided so as to include the surface 21 of the electrode wire 1.

The steel forming the core wire portion 10 contains, for example, 0.6 mass% to 1.1 mass% of carbon. The steel forming the core wire 10 may be, for example, a piano wire material specified in JIS standard G3502. The steel forming the core wire portion 10 has a uniform pearlite structure over the entire region thereof.

The copper-zinc alloy forming the clad layer 20 contains, for example, 60 mass% or more and 75 mass% or less of zinc. The coating layer 20 is composed of a gamma-phase single phase. That is, the copper-zinc alloy forming the clad layer 20 is composed of a γ -phase single phase. The copper-zinc alloy forming the coating layer 20 may contain one or more elements selected from the group consisting of silver (Ag), gold (Au), aluminum (Al), cadmium (Cd), and mercury (Hg) as an additive element. The coating layer 20 has a thickness of, for example, 1 μm or more and 8 μm or less.

The clad layer 20 has a surface roughness Ra of 0.08 μm or less in the circumferential direction (arrow α direction). The coating layer 20 has a surface roughness Ra of 0.08 μm or less in the longitudinal direction (arrow β direction).

The cladding layer 20 of the electrode wire 1 according to the present embodiment is composed of a γ -phase-single-phase copper-zinc alloy. This enables high-speed processing. In addition, since the clad layer 20 has a surface roughness Ra of 0.08 μm or less in the circumferential direction, a decrease in the machining accuracy is suppressed. Further, since the clad layer 20 has a surface roughness Ra of 0.08 μm or less in the longitudinal direction, a decrease in electrical conductivity is suppressed, and a decrease in processing accuracy is also suppressed. As a result, the electrode wire 1 becomes an electrode wire for wire electric discharge machining that can achieve both high-speed machining and high machining accuracy.

Fig. 2 shows the state of the metal structure (microstructure) of the region (cladding layer 20) near the surface of the electrode wire 1 in a cross section parallel to the longitudinal direction of the electrode wire 1 (the direction of arrow β in fig. 1). Fig. 3 shows the state of the metal structure (microstructure) of the region (cladding layer 20) near the surface of the electrode wire 1 in a cross section perpendicular to the longitudinal direction of the electrode wire 1 (the direction of arrow β in fig. 1).

Referring to fig. 2 and 3, the coating layer 20 covering the core wire portion 10 in contact with the surface 11 of the core wire portion 10 includes a surface region 28 as a region including the surface 21 and an inner region 29 as a region located on the inner peripheral side of the surface region 28 and in contact with the surface 11 of the core wire portion 10. The surface region 28 and the inner region 29 each have a polycrystalline structure containing a plurality of (a large number of) crystal grains 25A or 25B.

Referring to fig. 2, the crystal grains 25A in the surface region 28 have a shape longer in the longitudinal direction (arrow β direction) of the electrode wire 1 than in the radial direction. The ratio of the longitudinal length to the radial length of the crystal grains 25A in the surface region 28 is larger than the ratio of the longitudinal length to the radial length of the crystal grains 25B in the inner region 29. Such a metal structure reduces the surface roughness in the circumferential direction of the electrode wire 1 according to the present embodiment. In addition, the cracks 31 extending in the circumferential direction are suppressed, thereby reducing the surface roughness in the longitudinal direction, and also making it possible to ensure sufficient electrical conductivity. Specifically, the surface 21 of the electrode wire 1 contains 10 or less cracks 31 in the range of a length of 100 μm in the longitudinal direction of the electrode wire 1.

The number of cracks 31 may be checked, for example, by cutting the electrode wire 1 on a cross section parallel to the longitudinal direction and observing the cut cross section under a microscope. The number of cracks 31 in the range of a length of 100 μm in the longitudinal direction of the electrode wire 1 may be determined by observing a plurality of regions such as five regions each having a length of 100 μm in the longitudinal direction and calculating an average of the five regions. The surface 21 of the electrode wire 1 preferably contains 5 or less cracks 31, more preferably 0 cracks 31, in the range of a length of 100 μm in the longitudinal direction of the electrode wire 1, that is, for example, no cracks 31 are found when five regions are observed.

The cladding layer 20 of the electrode wire 1 according to the present embodiment has a surface roughness Ra of preferably 0.06 μm or less, more preferably 0.04 μm or less, in the circumferential direction. This further improves the machining accuracy.

In addition, the surface roughness Rz of the coating layer 20 of the electrode wire 1 according to the present embodiment in the longitudinal direction is preferably 0.50 μm or less, more preferably 0.30 μm or less, and further preferably 0.20 μm or less. In addition, the surface roughness Ra of the coating layer 20 of the electrode wire 1 according to the present embodiment in the longitudinal direction is preferably 0.06 μm or less, and more preferably 0.04 μm or less. This further suppresses a decrease in the electrical conductivity, and also further suppresses a decrease in the processing accuracy.

The surface roughness Ra and the surface roughness Rz mean values specified in JIS standard B0601. In the present application, the surface roughness in the circumferential direction is measured over a sampling length equal to the length (outer circumferential length) of one turn in the circumferential direction of the wire electric discharge machining electrode wire.

In addition, the roundness of the outer periphery of the cross section perpendicular to the longitudinal direction of the electrode wire 1 according to the present embodiment (the roundness of the surface 21 of the coating layer 20) is preferably 0.25 μm or less. This can further improve the machining accuracy. The circularity is more preferably 0.15 μm or less, and still more preferably 0.10 μm or less. The roundness refers to the difference between the radii of circles inscribed and circumscribed around the contour of the surface 21 in a cross-section perpendicular to the longitudinal direction of the electrode wire 1.

In addition, the electrode wire 1 according to the present embodiment preferably has an electrical conductivity of 8% IACS or more and 20% IACS or less. This enables the electrode wire 1 to have a suitable electrical conductivity. More preferably, the electrode wire 1 has an electrical conductivity above 9% IACS.

The surface hardness of the electrode wire 1 according to the present embodiment (the hardness of the surface 21 of the covering layer 20) is preferably 300HV to 600 HV. This enables the clad layer 20 to have sufficient strength. More preferably, the electrode wire 1 has a surface hardness of 400HV or more. More preferably, the electrode wire 1 has a surface hardness of 500HV or less.

The electrode wire 1 preferably has a tensile strength of 1800MPa to 3200 MPa. This suppresses breakage during wire electric discharge machining. More preferably, the electrode wire 1 has a tensile strength of 2000MPa or more and 3000MPa or less.

The electrode wire 1 preferably has a wire diameter of 20 μm or more and 200 μm or less. A wire diameter of 20 μm or more makes it easier to ensure sufficient strength. The wire diameter of 200 μm or less makes it easier to perform precision machining.

The area fraction of the clad 20 in a cross section perpendicular to the longitudinal direction of the electrode wire 1 is preferably 10% or more and 45% or less. This makes it easier to achieve the desired conductivity and discharge performance while ensuring sufficient tensile strength.

Next, an exemplary method for manufacturing the electrode line 1 according to the present embodiment will be described. Referring to fig. 4, in the method of manufacturing the electrode wire 1 according to the present embodiment, a raw steel wire providing step is first performed as a step (S10). In step (S10), for example, a steel wire composed of a piano wire material specified in JIS standard G3502 is provided. Specifically, referring to fig. 5, a raw steel wire 50 having an appropriate wire diameter is provided by considering a desired wire diameter of the electrode wire 1. The raw steel wire 50 has a circular cross section perpendicular to the longitudinal direction. The raw steel wire 50 is provided, for example, by a process including a rolling step and a drawing step.

Then, a wire drawing step is performed as a step (S20). In the step (S20), the raw steel wire 50 provided in the step (S10) is drawn. Thereby, the wire diameter of the raw steel wire 50 is adjusted so that a desired wire diameter of the core wire portion 10 of the electrode wire 1 is obtained after a step (S60) described later. The stock wire 50 may be subjected to a process of pidn. May be formed by heating the raw steel wire 50 to an austenitizing temperature (a)₁Point temperature) or more, and then quenching the raw material steel wire 50 to a temperature (M) higher than the martensite transformation start temperature_sPoint temperature) and the stock wire 50 is maintained in the temperature range to perform the process of making a dun. This transforms the steel structure of the raw material steel wire 50 into a fine pearlite structure having a small lamellar spacing.

Then, a copper layer forming step is performed as a step (S30). In step (S30), a copper layer (Cu layer) is formed on the surface of the raw steel wire 50 subjected to step (S20). Specifically, referring to fig. 6, a copper layer 52 is formed to cover the surface 51 of the raw steel wire 50.

The copper layer 52 may be formed, for example, by plating.

Then, a zinc layer forming step is performed as a step (S40). In step (S40), a zinc layer (Zn layer) is formed on the surface of the raw steel wire 50 subjected to step (S30). Specifically, referring to fig. 6, a zinc layer 54 is formed so as to cover a surface 53 of a copper layer 52 formed on a surface 51 of a raw steel wire 50. The zinc layer 54 can be formed by plating, for example.

The thicknesses of the copper layer 52 and the zinc layer 54 formed in steps (S30) and (S40) may be determined by considering the desired composition of the copper-zinc alloy forming the clad layer 20. In addition, the order of formation of the copper layer 52 and the zinc layer 54 is not limited to the above order; alternatively, the copper layer 52 may be formed after the zinc layer 54 is formed.

Then, the first heat treatment step is performed as a step (S50). In step (S50), the copper layer 52 and the zinc layer 54 formed in steps (S30) and (S40) are subjected to alloying treatment. Specifically, the raw steel wire 50 having the copper layer 52 and the zinc layer 54 is heat-treated, for example, by heating the raw steel wire 50 to a temperature range of 200 ℃ or more and 500 ℃ or less and holding the raw steel wire 50 for 1 hour or more and 6 hours or less. Thus, referring to fig. 6 and 7, the copper layer 52 and the zinc layer 54 are alloyed to obtain a clad layer 56 made of a copper-zinc alloy composed of a γ -phase single phase.

Then, a smooth wire drawing step is performed as a step (S60). In step (S60), the raw steel wire 50 having the coating layer 56 formed so as to cover the surface 51 is subjected to surface smooth drawing (smooth drawing). Specifically, the raw steel wire 50 on which the coating layer 56 is formed is drawn at a low area reduction rate, that is, an area reduction rate of 1% or more and 5% or less.

Then, a second heat treatment step is performed as a step (S70). In the step (S70), the clad layer 56 drawn in the step (S60) is heat-treated by, for example, heating the clad layer 56 to a temperature of 200 ℃ to 500 ℃ inclusive and holding the clad layer 56 for 1 hour to 6 hours inclusive. Thereby, an electrode wire 1 including the core wire portion 10 and the coating layer 20 covering the surface 11 of the core wire portion 10 is obtained. The raw steel wire 50 and the coating layer 56 correspond to the core wire portion 10 and the coating layer 20 of the electrode wire 1, respectively.

Here, the heat treatment in the step (S50) of the method of manufacturing the electrode wire 1 according to the present embodiment forms the coating layer 56 (coating layer 20) composed of the γ -phase single phase. By the formation of the coating layer 56 (coating layer 20) composed of a γ -phase single phase, large irregularities are left on the surface 21 of the electrode wire 1, which leads to a problem of a reduction in the machining accuracy if no measures are taken.

Therefore, in the present embodiment, the smooth drawing step is performed in step (S60). This causes the crystal grains 25A in the surface layer region 28 to be compressed in the radial direction of the electrode wire 1 and stretched in the longitudinal direction thereof, thereby achieving smoothing. Since the γ phase is brittle, if the area reduction rate after drawing exceeds 5%, a large number of cracks 31 extending in the circumferential direction are formed. As a result, although the surface roughness in the circumferential direction is reduced, the surface roughness in the longitudinal direction is increased due to the influence of the crack 31, and the electrical conductivity is also reduced. If the area reduction rate is 5% or less, the surface roughness of the surface 21 can be reduced while suppressing the formation of the crack 31. If the area reduction rate is 1% or more, the contact between the cladding 56 (cladding 20) and the drawing die is more reliably ensured over the entire circumference during drawing, so that the surface roughness in the circumferential direction can be more reliably reduced.

In the present embodiment, the second heat treatment step is performed as a step (S70). Although the step (S70) is optional, if the crack 31 is formed in the step (S60), the step (S70) repairs a part or all of the crack 31 by atomic diffusion, thereby further reducing the crack 31.

Therefore, the method of manufacturing the electrode wire 1 according to the present embodiment can be used to manufacture the electrode wire 1 capable of achieving both high-speed machining and high machining accuracy. Although the drawing step is performed as the step (S20) before the Cu layer forming step and the Zn layer forming step in the above embodiment, the drawing step may be performed after the Cu layer forming step and the Zn layer forming step and before the first heat treatment step.