电解射流—激光复合加工技术基础研究
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摘要
电解射流-激光复合加工技术是一项同时具备激光加工高效率及电解射流高表面质量的新型复合加工技术。其特点是借助电解射流加工“在线”消除激光加工产生的再铸层、残余应力、微裂纹,由于激光对待加工部位的辐照,使得电解液局部温度升高,进一步促进该区域的电化学作用,加强了电解射流加工的定域性,并伴随热化学及其它作用的影响去除材料。本文针对这项复合加工技术进行了以下研究:
(1)深入研究激光在介质中的传输特性,并对激光在空气、纯水和中性盐溶液中加工的力学效应进行了试验研究。试验结果表明:激光在短距离的液体介质中作用于靶材的力学效应是空气条件下的3倍以上,有利于去除金属熔化物;且激光在精细过滤后的工业盐溶液中传输可以达到与在纯水中接近的衰减效果。
(2)基于激光在中性盐溶液中衰减特性的研究、激光在射流中的传输原理和射流的稳定原理,并结合CFD仿真技术对喷射耦合腔体及喷嘴的流场特性进行了流体动力学仿真,研制了专用的电解射流-激光复合加工系统。
(3)利用电解射流-激光复合加工系统进行了复合加工成形规律研究。首先对电解射流加工进行了相关工艺试验,初步研究了各加工参数对加工效率和加工质量的影响,分析了电解射流加工的成形规律;其次,在电解射流加工试验的基础上,对脉冲电解射流-激光复合加工进行了试验研究,研究结果表明:复合加工孔孔壁具有较高的表面质量,基本无再铸层、微裂纹及热影响区等缺陷。
通过上述理论分析和试验研究,证实了电解射流-激光复合加工的可行性,为电解射流-激光复合加工工艺的进一步发展提供了试验依据。
Hybrid processing of electrochemical jet machining (EJM) and laser beam machining (LBM) is a new processing method, which obtains high efficiency of LBM and high surface quality of EJM. The course of EJM-LBM are that: the recast layer, heat affected zone and microcrack caused by LBM are removed by EJM, and radicalization of laser can accelerate the electrochemistry effect and enhance the localization of EJM, and besides LBM and electrochemical machining , action of thermochemistry and other effect may remove the material. The main research contents are as follows:
(1) The transmission properties of laser in medium are investigated, and experimental research on laser-induced mechanical effect in air, pure water and electrolyte is carried out. The results indicate that: laser-induced mechanical effect of metal target in the short distance liquid is three times more than that in air, and this is beneficial to remove the melt; the transmission effect of laser in the filtrated electrolyte approaches that in pure water.
(2) Based on the properties of laser attenuation in the electrolyte, the transmission properties of laser in jet and principle of jet stability, the special EJM-LBM test system is designed and manufactured, and the fluid dynamics properties of coupling jet cavity and nozzle are simulated by CFD software.
(3) The experimental study of shaping law is carried out by using the EJM-LBM test system,. First, the basic EJM experiment is conducted, and the influences of the machining parameters on surface quality and machining efficiency are investigated, and the shaping law of EJM is analyzed. Second, based on the experimental study of EJM, the basic experiment of EJM-LBM is carried out, and the results indicate that: the cliffs of holes obtain high surface quality and the recast layer, heat affected zone and micro-cracking are eliminated basically.
According to the above theoretical analysis and experimental investigation, the feasibility of EJM-LBM is verified. The research provides the experimental foundation for the further development.
(1)深入研究激光在介质中的传输特性,并对激光在空气、纯水和中性盐溶液中加工的力学效应进行了试验研究。试验结果表明:激光在短距离的液体介质中作用于靶材的力学效应是空气条件下的3倍以上,有利于去除金属熔化物;且激光在精细过滤后的工业盐溶液中传输可以达到与在纯水中接近的衰减效果。
(2)基于激光在中性盐溶液中衰减特性的研究、激光在射流中的传输原理和射流的稳定原理,并结合CFD仿真技术对喷射耦合腔体及喷嘴的流场特性进行了流体动力学仿真,研制了专用的电解射流-激光复合加工系统。
(3)利用电解射流-激光复合加工系统进行了复合加工成形规律研究。首先对电解射流加工进行了相关工艺试验,初步研究了各加工参数对加工效率和加工质量的影响,分析了电解射流加工的成形规律;其次,在电解射流加工试验的基础上,对脉冲电解射流-激光复合加工进行了试验研究,研究结果表明:复合加工孔孔壁具有较高的表面质量,基本无再铸层、微裂纹及热影响区等缺陷。
通过上述理论分析和试验研究,证实了电解射流-激光复合加工的可行性,为电解射流-激光复合加工工艺的进一步发展提供了试验依据。
Hybrid processing of electrochemical jet machining (EJM) and laser beam machining (LBM) is a new processing method, which obtains high efficiency of LBM and high surface quality of EJM. The course of EJM-LBM are that: the recast layer, heat affected zone and microcrack caused by LBM are removed by EJM, and radicalization of laser can accelerate the electrochemistry effect and enhance the localization of EJM, and besides LBM and electrochemical machining , action of thermochemistry and other effect may remove the material. The main research contents are as follows:
(1) The transmission properties of laser in medium are investigated, and experimental research on laser-induced mechanical effect in air, pure water and electrolyte is carried out. The results indicate that: laser-induced mechanical effect of metal target in the short distance liquid is three times more than that in air, and this is beneficial to remove the melt; the transmission effect of laser in the filtrated electrolyte approaches that in pure water.
(2) Based on the properties of laser attenuation in the electrolyte, the transmission properties of laser in jet and principle of jet stability, the special EJM-LBM test system is designed and manufactured, and the fluid dynamics properties of coupling jet cavity and nozzle are simulated by CFD software.
(3) The experimental study of shaping law is carried out by using the EJM-LBM test system,. First, the basic EJM experiment is conducted, and the influences of the machining parameters on surface quality and machining efficiency are investigated, and the shaping law of EJM is analyzed. Second, based on the experimental study of EJM, the basic experiment of EJM-LBM is carried out, and the results indicate that: the cliffs of holes obtain high surface quality and the recast layer, heat affected zone and micro-cracking are eliminated basically.
According to the above theoretical analysis and experimental investigation, the feasibility of EJM-LBM is verified. The research provides the experimental foundation for the further development.
引文
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