Electrode wire for wire electrical discharge machining and method for manufacturing the same

• Main Authors: IZUI ISAO, WASHIO NOBUYUKI, KIMOTO YOICHIRO, HASHIZUME KOICHI, YOSHIMOTO MASAKAZU, SATO HIROSHI
• Format: Patent
• Language: English
• Published: 15.07.2015
• Subjects: AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKINGWITHOUT ESSENTIALLY REMOVING MATERIAL; BASIC ELECTRIC ELEMENTS; CABLES; CONDUCTORS; ELECTRICITY; INSULATORS; MACHINE TOOLS; MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES,OTHERWISE THAN BY ROLLING; MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVINGMATERIAL; METAL-WORKING NOT OTHERWISE PROVIDED FOR; PERFORMING OPERATIONS; PUNCHING METAL; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING ORDIELECTRIC PROPERTIES; SUCH WORKING COMBINED WITH OTHER FORMS OF WORKING OF METAL; TRANSPORTING; WORKING OF METAL BY THE ACTION OF A HIGH CONCENTRATION OFELECTRIC CURRENT ON A WORKPIECE USING AN ELECTRODE WHICH TAKESTHE PLACE OF A TOOL

The present invention provides a high-speed machining electrode wire that can prevent shorts between the electrode wire and a workpiece, enhance the machining speed, and curb reduction of machining accuracy and generation of fine streaks on a machined surface and metal debris, by making it hard for particles of a copper-zinc diffusion alloy layer formed on the circumference surface of the electrode wire to fall off from the core. A wire material having a copper-zinc alloy layer, which is formed by action of thermal diffusion, and a zinc layer on its circumference surface is subjected to processes, including from a step of drawing the wire material to a step of reducing the diameter of the product, to reliably crash the copper-zinc alloy layer into particles. The particles are embedded in the circumference surface of a core to integrate the diffusion alloy layer and zinc layer with the core and prevent the diffusion alloy layer and zinc layer from falling off from the core. In addition, in order to cover cracks formed in the copper-zinc alloy layer during wire drawing with a zinc thin film, wire drawing is performed at temperatures appropriate for maintaining good malleability and ductility of zinc.