Ultrasonic Assisted Electronic-Discharging by Using Ceramic Fiber Punch for Electrode

碳化硅纤维的强度高于硬质钢，而硬度基本相同。因此，单一的碳化硅纤维是一种很好的超细冲床候选材料。在连续生产过程中，必须在无润滑剂的情况下进行超细穿孔。保证了陶瓷纤维的热稳定性，并通过形成不透氧的二氧化硅层稳定了碳化硅以防氧化。此外，陶瓷对金属的化学反应较少。因此，陶瓷纤维冲头具有较长的刀具寿命。本研究采用的纤维冲头制造方法，通过抛光和电解，称为FPBE工艺。该超细穿孔系统由个人计算机控制。计算机通过D/A转换器将控制信号发送到(1)移动冲头的压电致动器的电源，以及(2)在通过A/D转换器从(3)称重传感器…获得数据的同时缠绕穿孔箔的步进电机的驱动器单元更多的测量冲头力，以及(4)测量冲头行程的位移传感器，冲头速度由压电驱动器电压信号的变化来控制。金属箔进给由缠绕滚筒的直径和步进电机的旋转来设定。用于测量冲头行程的电涡流型位移传感器的最大测量长度为1 mm，由于非接触式，不能与冲头载荷测量相加。用于测量冲压载荷的测力元件的最大载荷为5N。对于非切割行程和冲孔行程，都测量了作用在测力元件上的力与冲头行程的关系，由两种载荷的差值得到了冲压净载荷。选择了厚度为17 mm的商用纯铝箔(A1100-H)、厚度为15微米的铍铜箔(25合金-1/4H)和厚度为8 PM的不锈钢箔(SUS304-H)作为穿孔材料。不锈钢箔是一种高强度材料，铍铜具有良好的变形能力，可用作高强度导电弹簧。对穿孔的观察表明，铝和铍铜的剪切表面大部分是光滑的，而不锈钢的剪切表面由66%的光滑和33%的断口组成，没有毛刺。经1000次攻丝后，铝箔和铍铜箔的冲头无裂纹、磨损或卡损，而不锈钢冲头只有裂纹。较少

The strength of the SiC fiber is higher than hard steels and its rigidity is approximately the same. Therefore, a single SiC fiber is a good candidate for an ultrafine punch. The ultrafine piercing must be conducted without lubricant in continuous processes. Thermal stability of the ceramic fiber is guaranteed, and SiC is stabilized against oxidation by forming an oxygen-impervious silica layer. Besides, ceramics are chemically less reactive to metals. Therefore, a long tool life is expected for ceramics fiber punches. The fiber punch making method employed in our study, by buffing and electrolysis, referred as FPBE process. The ultrafine piercing system is controlled by a personal computer. The computer sends control signals through a D/A converter to (1) a piezoelectric driver, the power source of the piezoelectric actuator, that moves the punch, and (2) the driver unit of the stepping motor that wind the pierced foil while obtaining data through an A/D converter from (3) a load cell … More measuring punch force, and (4) a displacement sensor measuring the punch stroke.Punch speed is controlled by the change of the piezoelectric driver voltage signal. Metallic foil feed is set by the diameter of the winding drum and the rotation of the stepping motor. The eddy current type displacement sensor for measuring the punch stroke has a maximum measuring length of 1 mm, and does not add up to the punch load measurement because of non-contact type. The load cell for measuring punch loads has the maximum load of 5 N. The forces acting on the load cell vs. punch stroke are measured for both the non-cutting and piercing strokes and the net punch load is obtained from the difference of the two loads. Commercial pure aluminum foil (A1100-H) of 17 thickness, beryllium copper foil (25 alloy-1/4H) of 15 um thickness and stainless steel foil (SUS304-H) of 8 p.m thickness were selected as materials to be pierced. The stainless steel foil is a high strength material and the beryllium copper has a good deformability and can be used as high strength conductive springs. Observation of the pierced hole shows that most of the sheared surface of the aluminum and beryllium copper is a smooth, whereas that of the stainless steel is composed of 66 % smooth and 33 % fractured surface area without burr. After 1000 taps, the punch used for the aluminum foil and beryllium copper foil had no cracks, wear or seizure whereas the stainless steel showed no wear but cracks. Less