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Basic shape milling of electrolytic red copper thin-walled electrodes

Curved thin-walled electrodes are widely used in the manufacturing of injection molds and die-casting molds. Their function is to form the sheet shape of products, such as heat sinks in motorcycle engines, aluminum alloy heat sinks in computer cases, and power supply heat dissipation windows in audio products. Shape etc. As shown in Figure 1.

 

1. The general characteristics of curved thin-walled electrodes are:

1. The electrode height is high, and the highest point is 22.0mm from the base plane.

2. The thickness of the electrode sheet is small, 1.5mm.

3. The top of the electrode is curved and must be finished with a spherical knife.

4. The distance between the sheets is 5.0mm. For narrow grooves, only tools with smaller diameters can be used to process the sheet shape.

2. Milling processing requirements for curved thin-walled electrodes:

1. Most of them are composed of narrow grooves and flakes with a certain height and even arrangement, and the top is in the shape of a complex curved surface;

2. Made of electrolytic red copper, the copper material has strong ductility.

3. When using a machining center or CNC milling to process the shape and the top of the curved sheet, it is easy to cause deformation and bending;

4. There are high requirements for process planning, cutting amount, and CAD/CAM programming parameter settings.

Based on the above characteristics, MasterCAM9.1 is used for programming and a machining center is used for milling. The following process steps are applied for CNC machining:

 

3. Basic shape processing

Because the electrode only needs to process the front side, the blank copper material is directly clamped on the flat-nose pliers (the flat-nose pliers have been calibrated) to start centering and setting the tool. As shown in Figure 2, the first step after tool setting is to use pocket plane grooving to remove the material in the area around the sheet.

Using imported ultra-fine particle full tungsten steel cutters, the amount of tool wear is extremely small, so the tool is not changed after rough machining, but the Contour machining method is directly used to finish the outer shape and lower datum down to size. The tool is φ16mm, the roughing tool speed is n=1200r/min, the cutting amount of each layer is 1.0mm, and the feed speed is νf=1000mm/min. The finishing speed n=1500r/min, the cutting amount on the back of each layer is 11.0mm, and the feed speed νf=300mm/min. The outline has been processed with an electric spark gap of 0.1mm on one side; temporarily retain the thin parts and the materials between the thin parts. The lower base is the reference centering frame during EDM, and the bevel is used to determine the direction of the electrode.

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