The working principles of special material processing mainly include EDM, wire cutting, electrolytic machining, ultrasonic machining, laser machining, electron beam machining and ion beam machining. These methods use different physical and chemical principles to achieve the processing of special materials.
Electrodischarge machining
Electrodischarge machining is the process of machining the workpiece through the electro-erosion effect of pulse discharge between the tool electrode and the workpiece electrode. This method can process various conductive materials, there is no cutting force during processing, and the pulse parameters can be adjusted arbitrarily. EDM uses the local high temperature generated by pulse discharge to melt and vaporize the metal, thereby achieving material removal.
Wire cutting
Wire cutting is the abbreviation of wire electrode EDM, which uses a moving electrode wire (such as molybdenum wire or copper wire) to cut along a predetermined trajectory. It is suitable for cutting complex and precise molds and other parts, and the processing accuracy can be controlled at about 0.01mm. Wire cutting removes metal materials through electric spark discharge, and controls the cutting trajectory through CNC programming.
Electrolytic machining
Electrolytic machining uses the electrochemical reaction principle of metal dissolution in electrolyte to perform forming processing. This method can process difficult-to-process materials without cutting force and cutting heat, but the electrolyte is corrosive to machine tools. Electrolytic machining is mainly used for processing surfaces such as mold holes, mold cavities, complex mold surfaces and deep small holes in mass production.
Ultrasonic machining
Ultrasonic machining uses ultrasonic vibration to enable the tool to process the workpiece. The abrasive suspension is impacted on the workpiece surface through high-frequency vibration to remove the material. This method is suitable for processing hard materials such as cemented carbide and ceramics, and has high processing accuracy and surface quality.
Laser machining
Laser machining uses a high-energy-density laser beam to irradiate the workpiece surface, causing the material to melt, vaporize or reach the ignition point quickly, thereby achieving material removal or modification. Laser machining is suitable for cutting, marking, welding and surface treatment of precision parts, and has the characteristics of high precision and high efficiency.
Electron beam machining and ion beam machining
Electron beam machining and ion beam machining use high-speed electrons or ion beams to bombard the workpiece surface to melt, evaporate or sputter and remove the material. These two methods are suitable for micro-machining and high-precision parts manufacturing, with extremely high processing accuracy and flexibility.