管电极电解加工关键技术研究
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摘要
航空发动机关键零部件群孔结构，孔径小（0.3~2mm），数量大（104~105），与零件表面法线方向夹角多变（0°~75°），孔形结构多样，多选用难加工材料，加工表面不允许有微裂纹、再铸层，给孔制造技术带来严峻挑战。难加工材料微小孔高效、高表面质量加工技术已成为国内外科学界和工程界的研究热点。
管电极电解加工，是利用金属材料在电解质溶液中发生阳极电化学溶解的原理，借助成形的工具阴极将工件加工成形的一种孔加工技术。管电极电解加工具有加工表面质量好，无冶金缺陷，无工具损耗，适合加工难加工材料小孔、群孔等特点，成为国内外最为关注的一项孔电解加工技术。本文针对管电极电解加工的若干关键技术进行研究。
（1）提出了正电位差辅助阳极管电极电解加工方法。建立正电位差辅助阳极管电极电解加工加工间隙内电场模型，仿真和试验结果表明，合适的电位差能够有效改善管电极过量进给时加工间隙内电场分布，减弱管电极过量进给引起的孔出口杂散腐蚀，抑制管电极电解加工对管电极进给深度的敏感性，提高了群孔电解加工精度。
（2）提出了脉动流场电解加工方法。建立脉动流场电解加工的多物理场耦合模型，采用有限元和动网格技术进行仿真分析，仿真和试验结果表明，采用优化的脉动流场可以促进电解加工的传热和材料蚀除速度，提高加工间隙均匀性，降低表面粗糙度；合适的脉动流场能够提高深小孔加工稳定性、加工精度，增大深小孔加工深度。
（3）制备出高耐用度绝缘涂层。根据弹性力学、界面力学原理，计算出管电极/绝缘层界面应力分布规律；通过管电极端部结构优化，降低了管电极/绝缘层界面应力，提高绝缘层耐用度；研究了表面粗化工艺对涂层结合强度的影响，进一步增强涂层/管电极结合力。
（4）研制出管电极电解加工系统。设计出龙门式三维移动平台、随动式密封结构，改善了机床密封性能；设计出精密数控转台，满足典型弧形零件群孔结构加工需求；开发了一套管电极电解加工软硬件控制系统，实现加工过程监控，并具备异常加工状态智能识别等功能。
（5）进行了典型群孔结构的管电极电解加工试验。设计了专用排管电极夹持工具，用于平面群孔、弧面群孔、平面群斜孔结构的加工；采用专用排管电极夹具和优化的工艺参数，成功加工出8×35平面阵列孔，8×27浮动瓦片模拟件弧面阵列孔，直径1mm、倾斜角45°的9×90多层阵列斜孔燃烧室壁试件，直径1.5mm、倾斜角10°、30°、55°的多角度多层阵列斜孔导流片试件。
Multiple holes of0.3mm to2mm in diameter,104to105in quantity, diverse cross-sectiongeometries and at divergent oblique angels to the normal direction of the surface in the range of0°to75°, are well applied in key components of aircraft engine. These holes in difficult-to-cut materials arerequired with no micro cracks or recast layers and bring much serious challenge to modern drillingtechnologies. Considerable attention has been paid to reliably producing these fine holes of highefficiency and surface integrity all over the world.
Shaped tube electrochemical machining (STEM) removes material by controlled anodicdissolution in an electrolytic cell and produces the workpiece into designed hole shapes via a shapedtube electrode. Inherent characteristics of STED, such as good surface integrity, absence of tool wearand metallurgical defects, suited simultaneously drilling of numerous small holes in difficult-to-cutmaterials, enable itself to be a promising and low-cost process for yielding these holes. Thedissertation focuses on key issues of shaped tube electrochemical machining.
(1) The electrochemical drilling technique applying a potential difference between an auxiliaryelectrode and the anode is proposed. An electric model for this drilling process is established toanalysis the current distribution in the machining gap. Simulation and experimental results indicatethat, when the tube electrode is excessively feed, a proper potential difference could diminish the straycurrent attack on the hole exit, lower the sensibility of the exit accuracy to excessive feeding depthand enhance the machining accuracy of multiple holes.
(2) Pulsating electrolyte flow is introduced to the electrochemical machining process. Amulti-physics model coupling of electric, heat and transport of diluted species was established tocalculate the effects of pulsating flow on electrochemical machining via the finite element method andthe moving mesh method. Both the simulation and experiments verified that using optimal pulsatingparameters, the heat transfer, the material removal rate, the machining gap uniformity and surfaceroughness are improved. Moreover, optimal pulsating flow in deep hole drilling could enhance theprocess stability, the machining accuracy as well as the maximum machining depth.
(3) The insulation coating with good durability is prepared. A computational method based onthe elastic mechanics and interface mechanics is proposed to estimate the distribution of theinterfacial stresses between the insulation coating and metal electrode substrate. Moreover, anelectrode tip structure is presented to reduce the interfacial stress and enhance the coating durability. And the coating adhesion to the electrode substrate is enhanced via the optimized surface rougheningtreatment.
(4) An electrochemical drilling system is developed. A three dimensional moving platform ofgantry structure as well as a follow sealing structure is designed to modify the unreliable sealingperformance of the traditional machine. A precise numerical-controlled turntable is designed for themachining of typical components with planar arrayed holes. Moreover, a computer system isdeveloped to control the hardware and software devices of the electrochemical drilling system, whichcould monitor the machining process and recognize the abnormal process status.
(5) Electrochemical drilling of multiple holes in typical structures is experimentally processed. Aspecialized tool was designed to fix the row electrode tubes for electrochemical drilling. Withoptimized process parameters, multiple holes in a planar array of8×35, a floating tile simulator withmultiple holes in an arc array of8×27, a trapped vortex combustor simulator with multiple obliqueholes in a planar array of9×90and at an oblique angle of45°, a flow deflector simulator withmultiple oblique holes in a planar array of5×90and at oblique angles of10°,30°and55°, weresuccessfully machined.
管电极电解加工，是利用金属材料在电解质溶液中发生阳极电化学溶解的原理，借助成形的工具阴极将工件加工成形的一种孔加工技术。管电极电解加工具有加工表面质量好，无冶金缺陷，无工具损耗，适合加工难加工材料小孔、群孔等特点，成为国内外最为关注的一项孔电解加工技术。本文针对管电极电解加工的若干关键技术进行研究。
（1）提出了正电位差辅助阳极管电极电解加工方法。建立正电位差辅助阳极管电极电解加工加工间隙内电场模型，仿真和试验结果表明，合适的电位差能够有效改善管电极过量进给时加工间隙内电场分布，减弱管电极过量进给引起的孔出口杂散腐蚀，抑制管电极电解加工对管电极进给深度的敏感性，提高了群孔电解加工精度。
（2）提出了脉动流场电解加工方法。建立脉动流场电解加工的多物理场耦合模型，采用有限元和动网格技术进行仿真分析，仿真和试验结果表明，采用优化的脉动流场可以促进电解加工的传热和材料蚀除速度，提高加工间隙均匀性，降低表面粗糙度；合适的脉动流场能够提高深小孔加工稳定性、加工精度，增大深小孔加工深度。
（3）制备出高耐用度绝缘涂层。根据弹性力学、界面力学原理，计算出管电极/绝缘层界面应力分布规律；通过管电极端部结构优化，降低了管电极/绝缘层界面应力，提高绝缘层耐用度；研究了表面粗化工艺对涂层结合强度的影响，进一步增强涂层/管电极结合力。
（4）研制出管电极电解加工系统。设计出龙门式三维移动平台、随动式密封结构，改善了机床密封性能；设计出精密数控转台，满足典型弧形零件群孔结构加工需求；开发了一套管电极电解加工软硬件控制系统，实现加工过程监控，并具备异常加工状态智能识别等功能。
（5）进行了典型群孔结构的管电极电解加工试验。设计了专用排管电极夹持工具，用于平面群孔、弧面群孔、平面群斜孔结构的加工；采用专用排管电极夹具和优化的工艺参数，成功加工出8×35平面阵列孔，8×27浮动瓦片模拟件弧面阵列孔，直径1mm、倾斜角45°的9×90多层阵列斜孔燃烧室壁试件，直径1.5mm、倾斜角10°、30°、55°的多角度多层阵列斜孔导流片试件。
Multiple holes of0.3mm to2mm in diameter,104to105in quantity, diverse cross-sectiongeometries and at divergent oblique angels to the normal direction of the surface in the range of0°to75°, are well applied in key components of aircraft engine. These holes in difficult-to-cut materials arerequired with no micro cracks or recast layers and bring much serious challenge to modern drillingtechnologies. Considerable attention has been paid to reliably producing these fine holes of highefficiency and surface integrity all over the world.
Shaped tube electrochemical machining (STEM) removes material by controlled anodicdissolution in an electrolytic cell and produces the workpiece into designed hole shapes via a shapedtube electrode. Inherent characteristics of STED, such as good surface integrity, absence of tool wearand metallurgical defects, suited simultaneously drilling of numerous small holes in difficult-to-cutmaterials, enable itself to be a promising and low-cost process for yielding these holes. Thedissertation focuses on key issues of shaped tube electrochemical machining.
(1) The electrochemical drilling technique applying a potential difference between an auxiliaryelectrode and the anode is proposed. An electric model for this drilling process is established toanalysis the current distribution in the machining gap. Simulation and experimental results indicatethat, when the tube electrode is excessively feed, a proper potential difference could diminish the straycurrent attack on the hole exit, lower the sensibility of the exit accuracy to excessive feeding depthand enhance the machining accuracy of multiple holes.
(2) Pulsating electrolyte flow is introduced to the electrochemical machining process. Amulti-physics model coupling of electric, heat and transport of diluted species was established tocalculate the effects of pulsating flow on electrochemical machining via the finite element method andthe moving mesh method. Both the simulation and experiments verified that using optimal pulsatingparameters, the heat transfer, the material removal rate, the machining gap uniformity and surfaceroughness are improved. Moreover, optimal pulsating flow in deep hole drilling could enhance theprocess stability, the machining accuracy as well as the maximum machining depth.
(3) The insulation coating with good durability is prepared. A computational method based onthe elastic mechanics and interface mechanics is proposed to estimate the distribution of theinterfacial stresses between the insulation coating and metal electrode substrate. Moreover, anelectrode tip structure is presented to reduce the interfacial stress and enhance the coating durability. And the coating adhesion to the electrode substrate is enhanced via the optimized surface rougheningtreatment.
(4) An electrochemical drilling system is developed. A three dimensional moving platform ofgantry structure as well as a follow sealing structure is designed to modify the unreliable sealingperformance of the traditional machine. A precise numerical-controlled turntable is designed for themachining of typical components with planar arrayed holes. Moreover, a computer system isdeveloped to control the hardware and software devices of the electrochemical drilling system, whichcould monitor the machining process and recognize the abnormal process status.
(5) Electrochemical drilling of multiple holes in typical structures is experimentally processed. Aspecialized tool was designed to fix the row electrode tubes for electrochemical drilling. Withoptimized process parameters, multiple holes in a planar array of8×35, a floating tile simulator withmultiple holes in an arc array of8×27, a trapped vortex combustor simulator with multiple obliqueholes in a planar array of9×90and at an oblique angle of45°, a flow deflector simulator withmultiple oblique holes in a planar array of5×90and at oblique angles of10°,30°and55°, weresuccessfully machined.
引文
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