JPS6161928B2 - - Google Patents

Description

Detailed Description of the Invention The present invention provides a novel method for manufacturing an electrode for electrical discharge machining, in which an electrode core material is formed from a photosensitive resin, and an electrode layer is coated on the surface of the electrode core material, and the electrode for electrical discharge machining It is related to.

Conventionally, electrodes for electrical discharge machining require highly precise molding of easily processable materials such as copper or graphite into a shape that matches the shape of the workpiece, and this requires processing such as grinding and filing. However, if the electrode shape is complex, it not only requires a lot of processing time but also has the disadvantage that processing becomes difficult.

Special Publication Showa 47-15320 that solved the above drawbacks.
, a method for manufacturing an electrode for electric discharge machining is provided, which is characterized in that a metal plate of a desired shape is produced by photoetching, and a large number of the metal plates are laminated and fixed.

However, in the above manufacturing method, the thickness of the metal plate is
Since the length is limited to around 0.1 mm, for example, 150 metal plates are required to make an electrode with a length of 15 mm, and each metal plate is coated with a photosensitizer, dried, baked, and heat-cured. A series of photoetching operations such as development and resist peeling must be repeated, which requires a great deal of effort and time. Furthermore, when laminating and fixing photoetched metal plates one by one, there is a possibility that the laminated electrodes are fixed while being distorted or bent. For this reason, even if an electrode with a complicated shape can be obtained, it is difficult to obtain a highly accurate electrode for electric discharge machining.

The present invention has been made in view of the above circumstances, and is a method for manufacturing an electrode for electric discharge machining, in which a laminated electrode core material is formed from a photosensitive resin, and an electrode layer is coated on this electrode core material by thermal spraying, plating, etc. The present invention aims to provide an electrode for electrical discharge machining using this method.

EMBODIMENT OF THE INVENTION Hereinafter, the embodiment concerning this invention and the electrode for electrical discharge machining by this are demonstrated. First, the outline of the photosensitive resin used in the manufacturing method of the present invention will be explained. Photosensitive resins are commercially available under names such as Tevista, APR resin, and Aronix, and are liquid resins that solidify when exposed to ultraviolet light. The relationship between the exposure time and the depth of solidification is as follows: When using a 500W xenon lamp light source, the depth from the resin surface to the deep part is approximately 3 mm after 1 minute, approximately 8 mm after 5 minutes, approximately 12 mm after 10 minutes, and approximately 16 mm after 20 minutes. solidify. The present invention is based on a method of solidifying a region corresponding to the cross-sectional shape of the electrical discharge machining electrode to be formed using this liquid resin, and stacking the solidified layers. Note that the electrode to be molded has the same cross-sectional shape as this cross-sectional shape transparently drawn on a transparent film, and the number of cross-sectional views into which the electrode is divided is determined by the complexity and accuracy of the electrode shape. However, no matter how complex the cross-sectional shape is, a single transparent film is sufficient as long as it is a columnar electrode and each part has the same size and the same cross-sectional shape. That is, the two embodiments shown in FIGS. 1 to 3 show the steps of the method for manufacturing an electrode for electrical discharge machining using one transparent film. FIG. 1 shows an electrode molding machine 10 for manufacturing electrodes for electrical discharge machining according to the present invention from photosensitive resin. is provided. Table 2 above is a pulse motor
The table is connected via a lower end bevel gear 4 on the rotating shaft 3 of the PM and a bevel gear 6 on the horizontal drive shaft 5, and the table is raised and lowered by forward and reverse rotation of the pulse motor PM. C is the control box for table 2, and it is a knob that sets the inching feed amount of table 2.
S ₁ , the full stroke setting knob S ₂ , the timer knob S ₃ that sets the jig interval for the jig feed amount, the setting knob S ₄ for the table continuous slow feed, the power switch S ₅ , the jig feed Continuous feed sorting switch S ₆
and table upward/downward feed selection switch.
Equipped with S ₇ . L _a is a light source of a 500 W xenon lamp, which is irradiated perpendicularly onto the top surface of the table 2 as parallel light through a condenser lens 7 . This light source L _a is designed to turn off when the table 2 is raised or lowered when the inching feed is set, and the upper and lower limit positions of the table 2 are determined by the proximity sensor L ₁ ,
Detected by L ₂ . F ₀ is a film plate that covers the top surface of the aquarium 1, and its transparent portion is processed to have a four-petal shape F ₁ that is the same cross-sectional shape as the electrode.
With this, the light beam passing through the film plate F ₀ can illuminate the upper surface of the table 2 in a petal shape F ₁ . Then, in the aquarium 1, there is a liquid resin photosensitive resin.
Inject HP until nearly full. Next, to explain the manufacturing process of the electrode core material with reference to Figure 2, prior to manufacturing, a film plate F ₀ is placed and fixed on the top surface of the water tank, and then the inching feed amount of the table 2 (per layer that is the unit thickness) is Set the solidified layer thickness) and the stop time (solidification time) using the respective knobs _S1 and _S3 . First, as shown in FIG. 2a, the table 2 is submerged and fixed by a unit thickness of h ₁ from the surface of the photosensitive resin HP, which is a liquid resin, and the light source L _a
The photosensitive resin HP is irradiated with light from the condenser lens 7 and the film plate F ₀ . Now, the photosensitive resin HP is solidified to a unit thickness h ₁ in the same shape as the pattern F ₁ of the transparent portion, and becomes solidified resin P ₁ . When the resin is sufficiently solidified, the timer causes the table 2 to be inched again by h ₁ and lowered to form the second layer of solidified resin P ₂ . Thereafter, as shown in FIG. 2b, the above operations are repeated until the solidified resin reaches a predetermined height h ₀ to form the electrode core material P ₀ of the multiple solidified layers h ₁ . The electrode core material P ₀ is taken out from the table 2 and washed with water in a shower W as shown in FIG. 2c. Thereafter, as shown in d of FIG. 2, the surface of the electrode core material P ₀ is coated with metal by forming an electrode layer M by, for example, copper plating or thermal spraying, in order to make the electrode core material P ₀ conductive. The electrode P ₀ ' for electrical discharge machining is manufactured through the above steps.

In the embodiment shown in FIG. 3, the transparent portion F ₁ ' of the film plate F ₀ is shaped as shown in the figure, and when this is adopted, the electrode P ₀ ″ for electric discharge machining as shown in b in FIG. That is, what is shown in FIG. 2 is a male electrode P ₀ ', and what is shown in FIG. 3 is a female electrode P ₀ ''.

The cross-sectional structures of the above two electric discharge machining electrodes P ₀ ′ and P ₀ ″ are shown in Figure 4 a and b, and the electrode core material P ₀ is made of multiple solidified layers h made by solidifying and stacking photosensitive resin HP. ₁
...and this surface is metal coated with a conductive layer M. According to the electrode structure manufactured as described above, although the electrode core materials are laminated in multiple layers, not only the interlayer adhesion is extremely excellent, but also the electrode shape can be formed with high precision.

The embodiments of the electric discharge machining electrode according to the present invention are not limited to the above two, and other embodiments are possible. For example, when manufacturing a conical electrode, the area of the transparent part F1 can be gradually increased or decreased by replacing the film plate _F0 for each solidified layer _h1 , or the area of the transparent part _F1 can be gradually increased or decreased. The transparent shape light rays irradiated onto the table 2 may be expanded or contracted to form an image. Of course, if the cross-sectional shape changes gradually for each solidified layer _h1 , a film plate _F0 for each layer is prepared and replaced when the table 2 is inched. Also, the electrode
When the current capacity to flow through P ₀ ′, P ₀ ″ is relatively large, fine metal powder is mixed into the photosensitive resin HP before solidification so that the current also flows through the electrode core material P ₀ . By solidifying it, it can be used as a conductive electrode core material.

When using the method of manufacturing an electrode for electrical discharge machining of the present invention, the photosensitive resin is solidified in units of thickness by irradiating the photosensitive resin with a light beam through a film plate having a transparent part having the same cross-sectional shape as the electrode, and the photosensitive resin is solidified in units of thickness. The desired electrode core material is formed by laminating many solidified layers, and then the surface of the electrode core material is coated with the electrode layer after washing with water. Therefore, electrodes for electrical discharge machining can be formed into any complex electrode shape in a short time. Moreover, since the adhesive properties between each laminated layer are excellent, the laminated electrode is unlikely to be distorted or solidified while being bent, making it possible to provide high-precision electrodes at low cost. .

Furthermore, when using the electrode for electrical discharge machining of the present invention, an electrode core material with a multilayer structure is formed from a photosensitive resin solidified for each unit thickness, and an electrode layer is formed on the surface of this electrode core material, so that interlayer adhesion is achieved. This method has the advantage of being highly accurate even with complex electrode shapes and providing low-cost electrodes.

[Brief explanation of the drawing]

FIG. 1 is a perspective view of an electrode forming machine for manufacturing the electrode of the present invention, FIG. 2 is a process diagram showing the manufacturing process of the electrode of the present invention, and FIG. 3 is a manufacturing process of the electrode of the present invention according to the second embodiment. FIG. 4 is a cross-sectional view of an electrode manufactured by the method of the present invention. 10...electrode forming machine, HP...photosensitive resin, _F0 ...film plate, _F1 , F1 _' ...transparent part, _h1 ...unit thickness,
L _a ... light source, P ₁ , P ₂ , P ₃ ... solidified resin serving as a solidified layer, P ₀ ... electrode core material, P ₀ ′, P ₀ ″ ... electrode for electrical discharge machining,
M...electrode layer.

Claims (1)

[Scope of Claims] 1. A photosensitive resin is solidified in units of thickness with light irradiated through a film plate having a transparent part having the same cross-sectional shape as the electrode, and a number of the solidified layers are laminated to form a desired electrode core. A method for manufacturing an electrode for electric discharge machining, which comprises forming an electrode core material, and subsequently coating the surface of the electrode core material, which has been washed with water, with an electrode layer. 2. An electrode for electric discharge machining, characterized in that an electrode core material having a multilayer structure is formed from a photosensitive resin solidified in units of thickness, and an electrode layer is formed on the surface of this electrode core material.