微铣刀在位制备方法研究
Study on On-site Preparation Technology of Micro-milling Tool

提出基于WEDG技术的微铣刀在位制备方法，将微铣刀的制备与使用结合起来，在同一台微细电火花加工机床上完成微铣刀的在位制备与在位铣削过程，可实现微铣刀的低成本高精度制备，同时避免微铣刀的二次装夹所造成的倾斜和偏心误差，提高微铣削整体质量。为验证基于WEDG技术的微铣刀在位制备工艺方法的可行性，基于自研μEM-200CDS2型双主轴三工位微细组合电加工机床平台，进行了微铣刀在位制备与在位铣削的实验研究。结合WEDG工艺特点对微铣刀进行材料选用与构型设计，实现了直径小于100 μm、刃口锋利的D型微铣刀的制备，并利用所制备微铣刀在位铣削出最小壁厚小于20 μm的一组薄壁结构。实验结果表明：基于WEDG技术的微铣刀在位制备方法在原理和技术上是可行的。
A novel method of micro-tools preparation with wire electro discharge grinding(WEDG) technology was presented. The method combines the manufacturing with the use of micro-milling tool, so the preparation and use process of micro-cutter would complete together on the same micro-EDM machine. In this way, the set-up errors caused by micro-cutter tilt and eccentricity errors could be avoided, and the overall quality of the parts would be increased. In order to verify the feasibility of on-site preparation technology of micro-milling tool via WEDG, a series of experiments were carried out based on the self-development μEM-200CDS2 double spindle three-position micro EDM platform. The influence of the tool material and geometric structure of micro-milling tool tip was analyzed, meanwhile, the carbide materials and the geometric structural of D shape were acquired which are suitable for WEDG processing. Finally the micro-milling tool with cutting edge diameter less than 100 μm were fabricated via WEDG, and a group of thin-walled structures with a minimum thickness less than 20 μm were machined with micro-milling. The results showed that the on-site preparation technology of micro-milling tool via WEDG is feasible