基于非水基电解液的钛合金微细电解加工工艺优化
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摘要
针对钛合金这种典型的难于传统机械加工的材料,电解加工能达到"以柔克刚"的目的,是解决钛合金加工难题的首选方案.但是钛存在自钝化的特性,如果使用常规的水基电解液进行钛合金的电解加工,其基体表面会持续生成氧化膜,降低加工精度,甚至导致加工无法进行.为了解决这一技术难点,本文尝试采用以乙二醇作为基体的电解液进行电解加工实验.并通过工艺优化实验探究了行走速度、初始加工间隙、脉冲峰值电压等参数对钛合金微细电解加工效果的影响.通过对比分析加工效果,最终确定出优化的工艺参数,并利用优选参数在钛板基体上加工出TJU字样,从而实现钛合金微细电解加工.
Electrochemical machining is a preferred method to manufacture difficult-to-cut materials such as titanium alloy. However,titanium is easily passivated. If a conventional water-based electrolyte is used,oxide film will instantly form on the surface,which will reduce the machining accuracy and even lead to the failure of processing. To solve this technical difficulty,a type of electrolyte based on ethylene glycol was used in this paper. Through the process optimization experiment,the influences of moving rate,initial inter-electrode gap,and pulse potential on the performance of the micro electrolytic machining of titanium alloy were investigated. By comparing and analyzing the machining performance,the optimum technological parameters were determined. Finally,the word"TJU" was processed on the titanium plates using the optimized parameters to confirm the utility of electrochemical micromachining using this ethylene glycol-based electrolyte.
Electrochemical machining is a preferred method to manufacture difficult-to-cut materials such as titanium alloy. However,titanium is easily passivated. If a conventional water-based electrolyte is used,oxide film will instantly form on the surface,which will reduce the machining accuracy and even lead to the failure of processing. To solve this technical difficulty,a type of electrolyte based on ethylene glycol was used in this paper. Through the process optimization experiment,the influences of moving rate,initial inter-electrode gap,and pulse potential on the performance of the micro electrolytic machining of titanium alloy were investigated. By comparing and analyzing the machining performance,the optimum technological parameters were determined. Finally,the word"TJU" was processed on the titanium plates using the optimized parameters to confirm the utility of electrochemical micromachining using this ethylene glycol-based electrolyte.
引文
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[2]Avvari M,Manjaiah M,Able M,et al.Optimization of hole characteristics during pulse Nd:YAG laser drilling of commercially pure titanium alloy[J].Lasers in Manufacturing&Materials Processing,2017,4(2):76-91.
[3]Hourmand M,Sarban A A D,Sayuti M.Characterizing the effects of micro electrical discharge machining parameters on material removal rate during micro EDMdrilling of tungsten carbide(WC-Co)[J].IOP Conference Series:Materials Science and Engineering,2017,241(1):012005.
[4]Wang Y,Yi F,Zhang T,et al.Design and property study of micro-slot optics[J].Optics Communications,2017,386:14-21.
[5]Bunoiu I,Mindroiu M,Manole C C,et al.Electrochemical testing of a novel alloy in natural and artificial body fluids[J].Annals of Anatomy-Anatomischer Anzeiger,2018,217:54-59
[6]李中.钛及钛合金在汽车上的应用[J].中国有色金属学报,2010,20(增1):1034-1038.Li Zhong.Applications of titanium and titanium alloys in automotive field[J].The Chinese Journal of Nonferrous Metals,2010,20(S1):1034-1038(in Chinese).
[7]Patel J B,Feng Z,Villanueva P P,et al.Quality enhancement with ultrasonic wave and pulsed current in electrochemical machining[J].Procedia Manufacturing,2017,10:662-673.
[8]Skoczypiec S.Discussion of ultrashort voltage pulses electrochemical micromachining:A review[J].International Journal of Advanced Manufacturing Technology,2016,87(1/2/3/4):177-187.
[9]Mitchell-Smith J,Clare A T.Electrochemical jet machining of titanium:Overcoming passivation layers with ultrasonic assistance[J].Procedia CIRP,2016,42:379-383.
[10]Qu N S,Fang X L,Li W,et al.Wire electrochemical machining with axial electrolyte flushing for titanium alloy[J].Chinese Journal of Aeronautics,2013,26(1):224-229.
[11]Liu W D,Ao S S,Li Y,et al.Effect of anodic behavior on electrochemical machining of TB6 titanium alloy[J].Electrochimica Acta,2017,233:190-200.
[12]Chen X L,Qu N S,Hou Z B.Electrochemical micromachining of micro-dimple arrays on the surface of Ti-6Al-4V with Na NO3,electrolyte[J].International Journal of Advanced Manufacturing Technology,2016,88(1):1-10.
[13]Liu W D,Zhang H,Luo Z,et al.Electrochemical micromachining on titanium using the NaCl-containing ethylene glycol electrolyte[J].Journal of Materials Processing Technology,2018,255:784-794.
[14]Fushimi K,Kondo H,Konno H.Anodic dissolution of titanium in chloride-containing ethylene glycol solution[J].Electrochimica Acta,2009,55(1):258-264.
[15]Fushimi K,Habazaki H.Anodic dissolution of titanium in NaCl-containing ethylene glycol[J].Electrochimica Acta,2008,53(8):3371-3376.
[16]Anasane S S,Bhattacharyya B.Experimental investigation on suitability of electrolytes for electrochemical micromachining of titanium[J].International Journal of Advanced Manufacturing Technology,2016,86:1-14.
[17]张超,荆光涛,向庆波,等.钛合金脉冲电解加工的电解液优选研究[J].现代制造工程,2017(11):110-114.Zhang Chao,Jing Guangtao,Xiang Qingbo,et al.The optimization research of electrolyte of titanium alloy pulse electrochemical machining[J].Modern Manufacturing Engineering,2017(11):110-114(in Chinese).
[18]孙宇博,丘珍珍.电解加工中电解液对钛合金TC4型面加工质量的影响研究[J].电加工与模具,2015(5):31-34.Sun Yubo,Qiu Zhenzhen.Study on influence of electrolyte on surface quality of TC4 workpiece in electrochemical machining[J].Electromachining&Mould,2015(5):31-34(in Chinese).
[19]Zhang H,Ao S S,Liu W D,et al.Electrochemical micro-machining of high aspect ratio micro-tools using quasi-solid electrolyte[J].International Journal of Advanced Manufacturing Technology,2017,91(9):1-9.
[20]Wang Y,Qu N,Zeng Y,et al.The fabrication of highaspect-ratio cylindrical nano tool using ECM[J].International Journal of Precision Engineering&Manufacturing,2013,14(12):2179-2186.
[21]孙立力,张长富,梁若云,等.弹性材料3J21微槽的微细电解加工研究[J].价值工程,2015(5):67-68.Sun Lili,Zhang Changfu,Liang Ruoyun,et al.Micro electrochemical milling machining technology for micro grooves of elastic material 3J21[J].Value Engineering,2015(5):67-68(in Chinese).