微坑阵列掩膜电解加工试验研究微坑阵列掩膜电解加工试验研究
|
摘要
为了解决机械零件表面织构的加工问题,并充分利用电解加工的优势,本文基于COMSOL Multiphisics软件进行了微坑阵列掩膜电解加工过程的仿真分析,开展了电解加工零件表面微织构的工艺试验研究,得到了具有微米级别直径与深度的表面阵列微坑,总结了普通直流加工电压与加工时间、脉冲电流加工频率与占空比、不同掩膜孔直径对微坑加工的工艺规律。试验结果表明:在加工时间12 s,脉冲电压12 V,占空比30%,脉冲频率3 000 Hz,掩膜孔径200μm的参数下,能得出表面质量最优的微坑。
In order to solve the manufacturing of surface texture on mechanical parts and make full use of the advantages of electrochemical machining, based on the COMSOL multiphisics software, the electrochemical machining of mask micro-dimples array simulation analysis and the electrochemical machining of surface texture on mechanical parts experience study were carried out. The diameter and depth in nano size on the surface micro-dimples array were available and the technological rule of micro-dimples machining with common DC( Direct current)processing voltage and processing time,processing impulse current frequency and duty cycle,different diameter of mask holes were carried out. The results showed that the optimal micro-dimples with surface quality is the processing time of 12 s,pulse voltage of 12 V,duty cycle of 30%,pulse frequency of 3 000 Hz,pore size of mask of 200 μm.
In order to solve the manufacturing of surface texture on mechanical parts and make full use of the advantages of electrochemical machining, based on the COMSOL multiphisics software, the electrochemical machining of mask micro-dimples array simulation analysis and the electrochemical machining of surface texture on mechanical parts experience study were carried out. The diameter and depth in nano size on the surface micro-dimples array were available and the technological rule of micro-dimples machining with common DC( Direct current)processing voltage and processing time,processing impulse current frequency and duty cycle,different diameter of mask holes were carried out. The results showed that the optimal micro-dimples with surface quality is the processing time of 12 s,pulse voltage of 12 V,duty cycle of 30%,pulse frequency of 3 000 Hz,pore size of mask of 200 μm.
引文
[1]邢军强,王凤翔,张殿海,等.高速永磁电机转子空气摩擦损耗研究[J].中国电机工程学报,2010,30(27):14-19Xing J Q,Wang F X,Zhang D H,et al.Research on rotor air friction loss of high-speed permanent magnet machines[J].Proceedings of the CSEE,2010,30(27):14-19(in Chinese)
[2]奚炳章.大型电机中圆柱表面摩擦损耗的探讨[J].大电机技术,1988,(6):20-24Xi B Z.Study on the friction loss of circular cylinder surface in a large electric machine[J].Large Electric Machine and Hydraulic Turbine,1988,(6):20-24(in Chinese)
[3]刘强,林乃明,邹娇娟,等.改善钢铁材料摩擦学行为的表面织构研究现状[J].表面技术,2016,45(5):41-50Liu Q,Lin N M,Zou J J,et al.Recent developments in improving tribological behaviors of iron and steel via surface texturing[J].Surface Technology,2016,45(5):41-50(in Chinese)
[4]李俊玲,陈平,邵天敏,等.葫芦形微凹坑对不锈钢表面摩擦学性能的影响[J].摩擦学学报,2016,36(2):207-214Li J L,Chen P,Shao T M,et al.The effect of gourdshaped surface texture on tribological performance of stainless steel[J].Tribology,2016,36(2):207-214(in Chinese)
[5]王静秋,王晓雷.表面织构创新设计的研究回顾及展望[J].机械工程学报,2015,51(23):84-95Wang J Q,Wang X L.State of the art in innovative design of surface texture[J].Journal of Mechanical Engineering,2015,51(23):84-95(in Chinese)
[6]张保森,张凯,周衡志.激光表面织构结构参数对其摩擦学性能的影响[J].热加工工艺,2014,43(24):129-132Zhang B S,Zhang K,Zhou H Z.Effect of laser surface texture structural parameters on tribological properties[J].Hot Working Technology,2014,43(24):129-132(in Chinese)
[7]万轶,熊党生.激光表面织构化改善摩擦学性能的研究进展[J].摩擦学学报,2006,26(6):603-607Wan Y,Xiong D S.Study of laser surface texturing for improving tribological properties[J].Tribology,2006,26(6):603-607(in Chinese)
[8]王文中,黄志祥,沈殿,等.圆柱形表面微坑阵列对点接触润滑摩擦性能的影响[J].摩擦学学报,2012,32(4):371-376Wang W Z,Huang Z X,Shen D,et al.Effect of the patterned cylindrical dimple array on the tribological performance of lubricated point-contacts[J].Tribology,2012,32(4):371-376(in Chinese)
[9]Kim G D,Loh B G.An ultrasonic elliptical vibration cutting device for micro V-groove machining:Kinematical analysis and micro V-groove machining characteristics[J].Journal of Materials Processing Technology,2007,190(1-3):181-188
[10]靳广林,虞宙,胡俊.激光表面微造型与凸起形貌摩擦性能研究[J].应用激光,2015,35(5):536-540Jin G L,Yu Z,Hu J.Laser surface texuring and the influence of bulges produced by laser surface texuring on the sliding friction[J].Applied Laser,2015,35(5):536-540(in Chinese)
[11]明平美,周维海,赵晨浩,等.极间柔性多孔物充填型活动掩膜电解加工微坑技术[J].中国科学:技术科学,2016,46(10):1005-1015Ming P M,Zhou W H,Zhao C H,et al.Active through-mask electrochemical machining with its interelectrode gap filled with flexible porous material[J].Science China Technological,2016,46(10):1005-1015(in Chinese)
[12]胡建华,汪炜.纯钛微细群孔的超声辅助光刻电解加工[J].中国机械工程,2008,19(22):2670-2672,2771Hu J H,Wang W.Ultrasound aided through-mask electrochemical micromachining of micro-hole array in titanium[J].China Mechanical Engineering,2008,19(22):2670-2672,2771(in Chinese)
[13]Wang G Q,Li H S,Qu N S,et al.Investigation of the hole-formation process during double-sided through-mask electrochemical machining[J].Journal of Materials Processing Technology,2016,234:95-101
[14]郭紫贵,凡进军.基于电场分析的掩膜电解加工试验研究[J].机械科学与技术,2011,30(6):1016-1019,1024Guo Z G,Fan J J.A study of through mask electrochemical machining with electric field analysis[J].Mechanical Science and Technology for Aerospace Engineering,2011,30(6):1016-1019,1024(in Chinese)
[15]傅秀清,康敏,鲜洁宇,等.电解车削加工流场的数值模拟及工艺试验研究[J].机械科学与技术,2014,33(5):693-696Fu X Q,Kang M,Xian J Y,et al.Research on the numerical simulation and experiments of the flow field in electrochemical turning[J].Mechanical Science and Technology for Aerospace Engineering,2014,33(5):693-696(in Chinese)
[2]奚炳章.大型电机中圆柱表面摩擦损耗的探讨[J].大电机技术,1988,(6):20-24Xi B Z.Study on the friction loss of circular cylinder surface in a large electric machine[J].Large Electric Machine and Hydraulic Turbine,1988,(6):20-24(in Chinese)
[3]刘强,林乃明,邹娇娟,等.改善钢铁材料摩擦学行为的表面织构研究现状[J].表面技术,2016,45(5):41-50Liu Q,Lin N M,Zou J J,et al.Recent developments in improving tribological behaviors of iron and steel via surface texturing[J].Surface Technology,2016,45(5):41-50(in Chinese)
[4]李俊玲,陈平,邵天敏,等.葫芦形微凹坑对不锈钢表面摩擦学性能的影响[J].摩擦学学报,2016,36(2):207-214Li J L,Chen P,Shao T M,et al.The effect of gourdshaped surface texture on tribological performance of stainless steel[J].Tribology,2016,36(2):207-214(in Chinese)
[5]王静秋,王晓雷.表面织构创新设计的研究回顾及展望[J].机械工程学报,2015,51(23):84-95Wang J Q,Wang X L.State of the art in innovative design of surface texture[J].Journal of Mechanical Engineering,2015,51(23):84-95(in Chinese)
[6]张保森,张凯,周衡志.激光表面织构结构参数对其摩擦学性能的影响[J].热加工工艺,2014,43(24):129-132Zhang B S,Zhang K,Zhou H Z.Effect of laser surface texture structural parameters on tribological properties[J].Hot Working Technology,2014,43(24):129-132(in Chinese)
[7]万轶,熊党生.激光表面织构化改善摩擦学性能的研究进展[J].摩擦学学报,2006,26(6):603-607Wan Y,Xiong D S.Study of laser surface texturing for improving tribological properties[J].Tribology,2006,26(6):603-607(in Chinese)
[8]王文中,黄志祥,沈殿,等.圆柱形表面微坑阵列对点接触润滑摩擦性能的影响[J].摩擦学学报,2012,32(4):371-376Wang W Z,Huang Z X,Shen D,et al.Effect of the patterned cylindrical dimple array on the tribological performance of lubricated point-contacts[J].Tribology,2012,32(4):371-376(in Chinese)
[9]Kim G D,Loh B G.An ultrasonic elliptical vibration cutting device for micro V-groove machining:Kinematical analysis and micro V-groove machining characteristics[J].Journal of Materials Processing Technology,2007,190(1-3):181-188
[10]靳广林,虞宙,胡俊.激光表面微造型与凸起形貌摩擦性能研究[J].应用激光,2015,35(5):536-540Jin G L,Yu Z,Hu J.Laser surface texuring and the influence of bulges produced by laser surface texuring on the sliding friction[J].Applied Laser,2015,35(5):536-540(in Chinese)
[11]明平美,周维海,赵晨浩,等.极间柔性多孔物充填型活动掩膜电解加工微坑技术[J].中国科学:技术科学,2016,46(10):1005-1015Ming P M,Zhou W H,Zhao C H,et al.Active through-mask electrochemical machining with its interelectrode gap filled with flexible porous material[J].Science China Technological,2016,46(10):1005-1015(in Chinese)
[12]胡建华,汪炜.纯钛微细群孔的超声辅助光刻电解加工[J].中国机械工程,2008,19(22):2670-2672,2771Hu J H,Wang W.Ultrasound aided through-mask electrochemical micromachining of micro-hole array in titanium[J].China Mechanical Engineering,2008,19(22):2670-2672,2771(in Chinese)
[13]Wang G Q,Li H S,Qu N S,et al.Investigation of the hole-formation process during double-sided through-mask electrochemical machining[J].Journal of Materials Processing Technology,2016,234:95-101
[14]郭紫贵,凡进军.基于电场分析的掩膜电解加工试验研究[J].机械科学与技术,2011,30(6):1016-1019,1024Guo Z G,Fan J J.A study of through mask electrochemical machining with electric field analysis[J].Mechanical Science and Technology for Aerospace Engineering,2011,30(6):1016-1019,1024(in Chinese)
[15]傅秀清,康敏,鲜洁宇,等.电解车削加工流场的数值模拟及工艺试验研究[J].机械科学与技术,2014,33(5):693-696Fu X Q,Kang M,Xian J Y,et al.Research on the numerical simulation and experiments of the flow field in electrochemical turning[J].Mechanical Science and Technology for Aerospace Engineering,2014,33(5):693-696(in Chinese)