电极内孔结构对钛合金方孔电解加工的影响
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摘要
为提高管电极电解加工钛合金方孔的加工稳定性和精度,建立了方孔加工间隙内电解液流动模型,分析了电极内孔形状及尺寸对加工区流场均匀性的影响规律,并进行了相关试验.结果表明:采用圆形内孔电极加工时加工区流场的分布比采用方形内孔电极加工时均匀;电极内孔横截面积越大,加工区流场的分布越均匀,加工稳定性和精度均得到提高;使用直径为2.7mm的圆形内孔电极可加工出平均加工间隙为286μm、加工间隙标准差为4.7μm、表面粗糙度为0.8μm的钛合金方孔.
In order to improve the stability and accuracy of shaped tube electrochemical drilling of square holes in titanium alloys,an electrolyte flow model was constructed for the machining gap of square holes. Then,the effects of the hollow hole shape and electrode size on the uniformity of flow fields in the machining gap were investigated.Finally,the corresponding experiments were conducted to evaluate the effects. The results show that the flow fields from the electrodes with circular hollow holes are more uniform than those from the electrodes with square hollow holes,and that the increase of the hollow hole size can improve the uniformity of flow fields as well as the machining stability and accuracy. In addition,a square hole in titanium alloys,which has a surface roughness of 0. 8 μm,a machining gap of 286 μm and a machining gap standard deviation of 4. 7 μm,was machined by using an electrode with a circular hollow hole of a diameter of 2. 7 mm.
In order to improve the stability and accuracy of shaped tube electrochemical drilling of square holes in titanium alloys,an electrolyte flow model was constructed for the machining gap of square holes. Then,the effects of the hollow hole shape and electrode size on the uniformity of flow fields in the machining gap were investigated.Finally,the corresponding experiments were conducted to evaluate the effects. The results show that the flow fields from the electrodes with circular hollow holes are more uniform than those from the electrodes with square hollow holes,and that the increase of the hollow hole size can improve the uniformity of flow fields as well as the machining stability and accuracy. In addition,a square hole in titanium alloys,which has a surface roughness of 0. 8 μm,a machining gap of 286 μm and a machining gap standard deviation of 4. 7 μm,was machined by using an electrode with a circular hollow hole of a diameter of 2. 7 mm.
引文
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[2]Sen M,Shan H S.A review of electrochemical macro-to micro-hole drilling process[J].Journal of Machine Tools and Manufacture,2005,45:137-152.
[3]王维.群小孔电解加工的关键技术研究[D].南京:南京航空航天大学机电学院,2010.
[4]Hewidy M S,Ebeid S J.Modeling the performance of ECM assisted by low frequency vibrations[J].Journal of Materials Processing Technology,2007,189(1/2/3):466-472.
[5]郭家诚.创新同轴喷吸法与电解加工之研究[D].台湾:云林科技大学机械工程系,2007.
[6]朱荻,曲宁松.电极平动式电解加工技术研究[J].机械工程学报,2001,37(5):105-109.Zhu Di,Qu Ning-song.Investigation on electrochemical machining with the orbital movement of electrode[J].Chinese Journal of Mechanical Engineering,2001,37(5):105-109.
[7]Hewidy M S,Ebeid S J,Rajurkar K P,et al.Electrochemical machining under orbital motion conditions[J].Journal of Materials Processing Technology,2001,109(3):339-346.
[8]王维,朱荻,曲宁松,等.群孔管电极电解加工均流设计及其试验研究[J].航空学报,2010,31(8):1667-1673.Wang Wei,Zhu Di,Qu Ning-song,et al.Flow balance design and experimental investigation on electrochemical drilling of multiple holes[J].Acta Aeronautica et Astronautica Sinica,2010,31(8):1667-1673.
[9]刘改红,李勇,陈旭鹏,等.微细电解加工用电极的侧壁绝缘及应用实验[J].电加工与模具,2009(4):28-31.Liu Gai-hong,Li Yong,Chen Xu-peng,et al.Side insulation of tool electrode and application in micro ECM[J].Electro Machining&Mould,2009(4):28-31.
[10]贾建利,范植坚,王亚军.叠加磁场方孔电解加工试验研究[J].电加工与模具,2007(2):28-31.Jia Jian-li,Fan Zhi-jian,Wang Ya-jun.Research on the superposed magnetic field ECM of square hole[J].Electro Machining&Mould,2007(2):28-31.
[11]徐庆,朱荻,徐正扬.整体叶盘通道电解加工流场均匀性[J].华南理工大学学报:自然科学版,2011,39(6):7-12.Xu Qing,Zhu Di,Xu Zheng-yang.Uniformity of flow field in electrochemical machining of blisk tunnel[J].Journal of South China University of Technology:Natural Science Edition,2011,39(6):7-12.
[12]王维,朱荻,曲宁松,等.管电极电解加工工艺过程稳定性研究[J].机械工程学报,2010,46(11):179-184.Wang Wei,Zhu Di,Qu Ning-song,et al.Investigation on the process stability of electrochemical drilling[J].Chinese Journal of Mechanical Engineering,2010,46(11):179-184.
[13]Wang Wei,Zhu Di,Qu Ningsong,et al.Electrochemical drilling inclined holes using wedged electrodes[J].International Journal of Advanced Manufacturing Technology,2010,47(9/10/11/12):1129-1136.
[14]Rubel A.Computations of the oblique impingement of round jets upon plane wall[J].AIAA Journal,1981,19(7):863-871.
[15]王建业,徐家文.电解加工原理及应用[M].北京:国防工业出版社,2001.
[16]Fujisawa T,Inaba K,Yamamoto M,et al.Multiphysics simulation of electrochemical machining process for threedimensional compressor blade[J].Journal of Fluids Engineering,2008,130:081602/1-8.