JPS6199687A - Manufacture of electrocast electrode - Google Patents

Abstract

PURPOSE:To manufacture electrocast electrode having no strain and high precision, by adhering an electrode sheet formed at the surface of a master pattern, and an electrode sheet attaching surface of reinforcing frame formed by full mold casting through thin layer of adhesive. CONSTITUTION:Mold surface of the master pattern 22 is Cu plated to form the electrode sheet 23. On the other hand, an Al reinforcing frame 27 formed in one body and having the electrode sheet attaching surface 27a is manufactured by full mold method by using decomposable model. Next, an adhering resin 28 is coated uniformly on said sheet 23 by about 1-2mm thickness, thereat, said frame 27 is pressed so that the surface 27a is brought in contact with said resin coated surface, to push out the excess resin 28, and extremely thin resin layer of about 1mm max, thickness is obtd. Thereafter, the resin is hardened, further a standard surface 29 is formed to the frame 27 based on the pattern 22, then the pattern 22 is peeled off to obtain the electrocast electrode 21 composed of the electrode sheet 23 and the reinforcing frame 27.

Description

DETAILED DESCRIPTION OF THE INVENTION (Industrial Field of Application) The present invention relates to a method of manufacturing an electroformed electrode used in electrical discharge machining and the like.

(Prior art) As an electroforming electrode conventionally used, for example, the one shown in Fig. 2 (
There are some as shown in a). This electroformed electrode 1 is manufactured as follows. That is, as shown in FIG.
Apply to a thickness of 2IiI11, attach glass cloth, cloth, etc. on top of it, and then apply resin to a thickness of 2 to 3mm+.
Apply to a thickness of . Then, on top of that, the glass cloth, cloth, etc. and resin are alternately laminated by 5 to 6 layers,
A laminate 4 for reinforcing the electrode plate as shown in FIG. 2 (cl) having a total thickness of about 10 to 15 mm+ is formed.

Next, a reinforcing frame 7 constructed by welding iron pipes 5 and iron angles 6 as shown in FIG. 2 Fdl is fixed on top of this laminate 4 with resin 8 (see FIG. 3). After that, 24
After leaving it for a while to completely cure each resin, use the mother mold 2 as a reference? A reference surface 9 is formed from resin on the di-strength frame 7 to serve as a mounting surface when it is attached to an electric discharge machining device or the like (see FIG. 2 fal). Next, after finishing this reference surface 9 precisely by milling etc., the reinforcing frame 7 is
The matrix 2 is fixed on the measuring device 10, and then the matrix 2 is peeled off from the electrode plate 3 using a large hydraulic tensioner 11, and the reference surface resin layer 9 is removed.
, an electroformed electrode 1 consisting of a reinforcing frame 7, a laminate 4, and an electrode plate 3 is manufactured.

(Problems to be Solved by the Invention) However, in the conventional electroformed electrode as described above, the electrode plate was reinforced with a thick laminate made of a large amount of resin, glass cloth, cloth, etc. However, there were problems in that it was difficult to obtain the required accuracy due to curing distortion, and it was also difficult to maintain accuracy due to distortion due to aging of the resin. Furthermore, when peeling the electrode plate from the matrix, it cannot be peeled off unless a large jack is used and a large force is applied. Therefore, there was a problem in that the reinforcing frame could not withstand such a large load, and strain spread from the reinforcing frame to the entire electroformed electrode.

(Means for Solving the Problems) This invention was made by focusing on such conventional problems, and includes a step of forming an electrode plate by coating the mold surface of a matrix with copper, and A process of forming a reinforcing frame with a shape similar to the surface on which the reinforcing frame is mounted by full mold casting, a process of bonding the electrode plate of the matrix and the electrode plate mounting surface of the reinforcing frame through a thin layer of adhesive, and By providing a method for manufacturing an electroformed electrode, the method includes the steps of processing a reference surface, and peeling off a matrix from a reinforcing frame and an electrode plate that are bonded to each other.
This is an attempt to solve the above problems.

(Example) The present invention will be explained below based on the drawings.

FIGS. 1(a)-U) are diagrams showing one embodiment of the method of the present invention.

First, a copper-plated electrode plate is formed on the mold surface of the master die 22 as shown in Figure Ta1. In addition, divided models 24a and 24b of the reinforcing frame of the electrode plate as shown in FIG.
is manufactured from Styrofoam. Next, as shown in Figure FD1, a cotton cloth 25 is pasted on the electrode plate, and is sufficiently impregnated with a solvent 26 such as thinner. Then, the 7-hole strong frame model 24 b made of expanded polystyrene is pressed against the electrode plate 23 from above the cotton cloth 25 for about 5 minutes (as shown in Figure a1). b
By repeating the pressing operation 3 to 4 times while replenishing the solvent 26 to the cotton cloth etc. 25, the cotton cloth etc. 2 of the reinforcing frame model 24b is
The surface in contact with the electrode plate 4 is melted by the solvent 26 and becomes rough, and has a shape similar to the surface shape of the electrode plate 4. Next, this Styrofoam model 24 a
, 24b is used to form an integrally molded aluminum reinforcing frame 27 as shown in Figure +f1 by a full mold aluminum casting method. The electrode plate attachment surface of the reinforcing frame 27, ie, the surface 27a corresponding to the surface of the model 24b that has been dissolved by the solvent, has a large surface roughness due to the transfer of the surface shape of the model 24b.

Next, as shown in Figure g1, adhesive resin 28 is uniformly applied on the electrode plate 23 to a thickness of about 1 to 2 mm, and the reinforcing frame 27 is attached so that the electrode plate mounting surface 27a is attached to the electrode plate 23. As a result, the excess adhesive resin 28 is pushed out from between the electrode plate 23 and the reinforcing frame 27 as shown in Figure h1, and the adhesive resin 28 is pushed out by at most 1 mm. Therefore, after removing the extruded excess resin, the resin 28 is left to completely harden for about 24 hours.At that time, the resin 28 is cured as described above. Since the amount is extremely small, the curing strain is negligible.After the resin 28 is completely cured, a reference surface 29 is formed on the reinforcing frame 27 by milling using the matrix 22 as a reference as shown in Figure tJ1. Next, as in the conventional case, use a large jack to attach the matrix n to the electrode plate 23.
By peeling it off, a Ti cast electrode 21 is completed, as shown in Figure 11, which consists of an electrode plate 23 and a reinforcing frame r bonded together via a thin resin layer. Although a large load is applied to the electroformed electrode 21 when the matrix 22 is peeled off from the electrode plate, the reinforcing frame 27 is an integrally formed aluminum cast product and has high strength. The surface roughness of the electrode plate mounting surface 27a of the strong frame 27 is large, and the reinforcing frame 27 and the electrode plate ridge are firmly bonded via the resin 28, so that the electroformed electrode 21 is slightly out of alignment. No distortion occurs. Furthermore, since there is little 1H fat 28, distortion due to aging is negligible, and there is no effect on the accuracy of the electroformed electrode 21.

FIG. 4 shows another embodiment.

For example, in an electroformed electrode 31 whose electrode plate has a substantially conical shape as shown in FIG. There is a problem in that it is difficult to push out from between the frame 37. Therefore,
As shown in FIG. 4, holes 36 for removing resin are provided at appropriate positions on the electrode plate mounting surface of the reinforcing frame 37, and the electrode plate is attached to the reinforcing frame 37.
33 using a clamping device 39, the excess resin 38a can be sufficiently removed through the hole 36. The other steps are similar to the embodiment shown in FIG. 2 above.

(Effects of the Invention) As described above, according to the present invention, the step of forming an electrode plate by plating copper on the mold surface of the mother mold, and the reinforcing frame having a shape similar to the surface on which the electrode plate is attached are completely completed. A process of forming by mold casting, a process of adhering the electrode plate of the matrix and the electrode plate mounting surface of the reinforcing frame through a thin layer of adhesive, a process of processing a reference surface on the reinforcing frame, The manufacturing method for electroformed electrodes, which includes the process of peeling the matrix from the reinforcing frame and electrode plate, significantly reduces the amount of adhesive used for electroformed electrodes compared to conventional methods, and increases the strength of the reinforcing frame itself. In addition to significantly increasing the resistance, it is possible to bond the electrode plate and the reinforcing frame more firmly. As a result, the curing distortion of the adhesive and distortion due to aging becomes negligible.

Since mold release strain does not occur when the mother mold and the N-electrode plate are peeled off, a highly accurate electroformed electrode can be obtained.

[Brief explanation of drawings]

1(a) to U) are explanatory diagrams of each manufacturing process in an embodiment of the Ml electroformed electrode manufacturing method according to the present invention, and FIG.
Figures (al to (dl) indicate conventionally used electroformed electrodes, +a) is an overall perspective view of the electroformed electrode, (bl is a perspective view of the electrode plate and matrix, +C1 is the matrix and electrode plate) 3 is a front sectional view of the electrode plate reinforcing laminate, (d) is a perspective view of the ili strong frame, and FIG. 3 is a state in which the electrode plate of the electroformed electrode shown in FIG. An explanatory diagram, FIG. 4 is a cross-sectional explanatory diagram of a matrix electrode plate and a reinforcing frame showing another embodiment of the method for manufacturing an electroformed electrode according to the present invention, and FIG. It is a perspective view of an electroformed electrode having a shape suitable for 21.31--electroformed electrode, 22--matrix, edict, o--...-electrode plate, Nail, 37...--Reinforcement frame, 27 a--1.-Electrode plate mounting surface of reinforcement frame, 2B-
--1 Adhesive (resin), 29...Reference surface.

Claims (1)

[Claims] A step of forming an electrode plate by plating the mold surface of the mother mold with copper, a step of forming a reinforcing frame having a shape similar to the surface on which the electrode plate is attached by full mold casting, and an electrode of the mother mold. A step of adhering the plate and the electrode plate mounting surface of the reinforcing frame through a thin layer of adhesive, a step of processing a reference surface on the reinforcing frame, and a step of peeling the matrix from the reinforcing frame and electrode plate that are bonded to each other. A method for manufacturing an electroformed electrode, comprising the steps of: