磨料水射流光整加工及试验装置的研究
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摘要
磨料水射流复合电解光整加工是在磨料水射流作用的基础上复合电解加工。含有磨料的电解液从喷嘴喷出，在喷嘴与工件之间施加电解电压，电压范围为30～1000V，工件表面材料在电解和磨料水射流复合作用下被去除掉。
由于磨料价格昂贵，需要反复利用，因此对液-固相进行分离。使之从零件上清除下来的切屑、油污，尘埃等杂物过滤出去。
本课题的目的是建立一套磨料水射流复合试验装置，在这套装置上进行磨料水射流复合电解作用光整加工试验及其应用。通过分别对磨料水射流和电解复合磨料水射流采用正交试验及分析，验证可能影响加工效果的主要因素，他们包括靶距、射流压力、喷射倾角、加工时间、磨料粒度、电解电压以及电解液等因素。通过试验得出各因素对零件加工的影响规律，其中，靶距对零件的加工去除量有一定的影响，特别是对电解作用的电解电流影响较大；射流压力是一重要参数，对零件的表面粗糙度以及加工去除量影响较大；在试验角度±20°范围内，喷射倾角对加工效果几乎无影响；磨料粒度对零件加工以后的表面粗糙度和去除量均有影响，也是加工效率的重要标志；电压对电解的强弱起关键性作用，本文还针对各加工工艺参数的作用机理进行初步探讨，在进一步试验中，射流电压还可以更高一些。电解磨料水射流光整加工及试验装置具有参考意义和实用价值。
The process of abrasive water jet (AWJ) compound with electrolytic machine is based on AWJ. The nozzle of AWJ and the work piece is connected with the abrasive water jet and cathode of a DC power resource .The material of the work piece could be removed by AWJ and the function of electrolysis.
The process of liquid-solid separation helps to filter such refuse ascutting scraps, greasy filths and dust from the spare parts and avoid the cost of abrasive materials. The purpose of this paper is to establish a set of compound experiments of abrasive water jet in which the electrolytic process of abrasive water jet is conducted and applied and to explore which factors of EAWJ have notable effect, and how to bound the variety range of those factors. By orthographical experiments and the analysis, to AWJ and EAWJ process, the notable effect factors have been selected . The standoff has some effect on cutting quality of work piece. The rate of material remove is influenced by the volume of electrolytic current. The pressure of water jet is one of the important factors that influences both the rate of material remove and the roughness of the work piece surface. Abrasive granularity has great influence on the work piece surface and the rate of material remove . The bigger abrasive granularity is, the larger of the roughness is and so is the volume of material remove. The voltage of the DC power resource (<360V) is a key factor that influences the current of the electrolysis. The angle of the nozzle to the work piece is not effective within 20 . In the further experiment, the pressure of the water jet could be increased and the electrolyte could be NaCl solution.
The result of the experiment can be used to adjust the parameters of EAWJ process and can be used as a basis to design the equipment of EAWJ process.
由于磨料价格昂贵，需要反复利用，因此对液-固相进行分离。使之从零件上清除下来的切屑、油污，尘埃等杂物过滤出去。
本课题的目的是建立一套磨料水射流复合试验装置，在这套装置上进行磨料水射流复合电解作用光整加工试验及其应用。通过分别对磨料水射流和电解复合磨料水射流采用正交试验及分析，验证可能影响加工效果的主要因素，他们包括靶距、射流压力、喷射倾角、加工时间、磨料粒度、电解电压以及电解液等因素。通过试验得出各因素对零件加工的影响规律，其中，靶距对零件的加工去除量有一定的影响，特别是对电解作用的电解电流影响较大；射流压力是一重要参数，对零件的表面粗糙度以及加工去除量影响较大；在试验角度±20°范围内，喷射倾角对加工效果几乎无影响；磨料粒度对零件加工以后的表面粗糙度和去除量均有影响，也是加工效率的重要标志；电压对电解的强弱起关键性作用，本文还针对各加工工艺参数的作用机理进行初步探讨，在进一步试验中，射流电压还可以更高一些。电解磨料水射流光整加工及试验装置具有参考意义和实用价值。
The process of abrasive water jet (AWJ) compound with electrolytic machine is based on AWJ. The nozzle of AWJ and the work piece is connected with the abrasive water jet and cathode of a DC power resource .The material of the work piece could be removed by AWJ and the function of electrolysis.
The process of liquid-solid separation helps to filter such refuse ascutting scraps, greasy filths and dust from the spare parts and avoid the cost of abrasive materials. The purpose of this paper is to establish a set of compound experiments of abrasive water jet in which the electrolytic process of abrasive water jet is conducted and applied and to explore which factors of EAWJ have notable effect, and how to bound the variety range of those factors. By orthographical experiments and the analysis, to AWJ and EAWJ process, the notable effect factors have been selected . The standoff has some effect on cutting quality of work piece. The rate of material remove is influenced by the volume of electrolytic current. The pressure of water jet is one of the important factors that influences both the rate of material remove and the roughness of the work piece surface. Abrasive granularity has great influence on the work piece surface and the rate of material remove . The bigger abrasive granularity is, the larger of the roughness is and so is the volume of material remove. The voltage of the DC power resource (<360V) is a key factor that influences the current of the electrolysis. The angle of the nozzle to the work piece is not effective within 20 . In the further experiment, the pressure of the water jet could be increased and the electrolyte could be NaCl solution.
The result of the experiment can be used to adjust the parameters of EAWJ process and can be used as a basis to design the equipment of EAWJ process.
引文
1 沈忠厚著，水射流理论与技术，山东：石油大学出版社，1998．50～66
2 薛胜雄等著．高压水射流技术与应用，北京：机械工业出版社，1998，8
3 R. Carford, J. Kaminski etc .Chip control in tube turning using a high-pressure water jet. Processing Institute of Mechanical Engineering. Part B Manufcture Engineering .VOL. 212,1998.
4 J Ye and R Kovacevic. Turbulent solid-liquid flow through the nozzle of premixed abrasive water jet cutting systems. Processing Institute of Mechanical Engineering. Part B Manufacture Engineering. VOL. 213,1999
5 R Kovacevic, H. S Kwak and R S Mohan. Acoustic emission sensing as a tool for understanding the mechanisms of abrasive water jet drilling of difficult-to-machine materials, Processing Institute of Mechanical Engineering. Part B Manufacture Engineering .VOL. 212,1998.
6 M. Hashish. Controlled-depth milling of isogrid structures with AWJs. Journal of Manufacturing Science and Engineering. February 1998,VOL, 120
7 P. Meng. E.S. Gekin, M.C. Leu, F. Li and L. Tismeneskiy. An analytical and experimental study of cleaning with moving waterjets. Journal of Manufacturing Science and Engineering. August 1998, VOL, 120
8 M. C. Len, P. meng, E.S. Geskin and L, Tismeneskiy .Mathematical modeling and experimental verification of stationary waterjet cleaning process. Journal of ManuFacturing Science and Engineering .August 1998, VOL. 120
9 R. E. Williams. Acoustic emission characteristics of abrasive flowmachining. Journal of Manufacturing Science and Engineering .May 1998. VOL. 120
10 Eugene B. Nebeker, Ph.D., and John B. Cramer. Visualization of the central core of high-speed water jets an infrared thechnique.Proceedings of thesecond .U.S. water jet conference. May 1983,90～98
11 Dr.M. Mazurkiewiez. An analysis of one possibility for pulsating a high pressure water jet.Proceedings of the second U.S. water jet conference. May 1983,17～27
12 J.L. Evers, D. Leddingfield and J.Y. Yuh. Dimensionless pipe length analysis for jet modulation systems .Proceedings of the second U.S. water jet conference.May 1983,3～16
13 C.L. Kling, F.G. Hammitt. A photograph study of spark in ducted cavitations bubble collapse. Trans ASME, J Basic Engr, 1972,94(4).
14 V E Johnson, A F Conn, et al, Self-resonating caviating jets . 6th Int Symp on Jet Cutting Technology ,1982.
15 V E Johnson, et al. Cavitating and structured jet for mechanical bits to increase drilling rate. J Ener Eng ,1984
16 Cohen J, Wygnanski I. The evolution of instabilities in the axisymmetric jest. Jet Fluid Mech,1987
17 Dimotakis P E, et al. Structure and dynamics of round turbulent jets. Physics Fluid,1983.
18 Agul J C, Hesselink L. Flow visualization and numerical analysis of acoflowing jet. Jet Fluid Mach,1988
19 (英)狄更逊W等．锥形水射流钻孔．高压水射流，1988(1)28～32
20 (日)中西涉等．高压喷射注浆加固地基RJP工法．喷射技术，1997，1(23)；5～11
21 宋拥政，温效康，梁志强．磨料水射流的切割机制．机械工程学报，1997，6：102～107
22 候健，韩育礼．超高压磨料水射流切割系统试验研究．兵工学报，2000，8，第21卷：253～256
23 遇罗文．高压水射流切割技术和前混切割设备．新技术新工艺，1997，6
24 赵伟、刘晓冰、朱派龙．制造业的一枝奇葩—高压水射流加工技术．机械设计与制造工程，1999，3：1～2
25 史绍熙、林玉静、杨延相，杜青．影响空心旋转液体射流初始阶段运动的无量纲参数的分析．工程热物理学报，2000，7
26 杨延相，林玉静，史绍熙．旋转喷嘴中空旋转射流近区域流动的研究．应用力学学报，2000，6
27 杨延相，林玉静，杜青，史绍熙．空心旋转液体射流初始阶段特性的实验研究．工程热物理学报，2000，6
28 刑茂，赵阳升．高压旋转射流的三维有限元数值模拟研究．太原理工大学学报，2000，9
29 张作龙，梁忠民，高压淹没水射流破岩实验研究．石油矿场机械，2000，5：26～30
30 杨永印，沈忠厚，王瑞和，周卫东．旋转磨料射流破岩钻孔试验研究。石油钻探技术，1999，4
31 步玉环，周卫东，玉瑞和．岩性对旋转射流破岩成孔影响规律的研究，石油钻探技术，2000，8
32 蒋海军，廖荣庆．自激振荡脉冲射流机理探讨．西南石油学院学报，1998，3，第20卷．
33 唐川林，张风华等．它激剪切流动诱发振荡射流的研究．西南石油学院学报，2000，1第22卷：1～4
34 杨建明．电解磨料喷射复合抛光工艺的研究与应用．机械制造，1997，11：14～15
35 (美)J.R.罗思著．工业等离子体工程，第Ⅰ卷：基本原理．北京：科学出版社，1998
36 Tikhomirov R V et al.High -pressure Jet Cutting. New York: ASME 1992
37 余常昭编．紊动射流．北京：高等教育出版社，1993：31～35
38 董允等编著．现代表面工程技术．北京：机械工业出版社，1999，12：43～57
39 建业，徐家文编著．电解加工原理及应用．北京：国防工业出版社，200l，1
40 哈尔滨工业大学刘晋春，赵家齐主编．特种加工．北京：机械工业出版社，1996，5：79～109
41 姬振豫编著．正交设计，天津：天津科技翻译出版公司．1994，4
42 赵文珍主编．材料表面工程导论．西安：西安交通大学出版社．1998，10
43 成建联，宋国英，李福援．磨料水射流抛光工艺的试验研究．2001年中国机械工程学会年会暨第九届全国特种加工学术年会论文集(特种加工技术)．北京：机械工业出版社．2001，11
45 袁哲俊，王先逵主编．精密和超精密加工技术．北京：机械工业出版社．1999，7
2 薛胜雄等著．高压水射流技术与应用，北京：机械工业出版社，1998，8
3 R. Carford, J. Kaminski etc .Chip control in tube turning using a high-pressure water jet. Processing Institute of Mechanical Engineering. Part B Manufcture Engineering .VOL. 212,1998.
4 J Ye and R Kovacevic. Turbulent solid-liquid flow through the nozzle of premixed abrasive water jet cutting systems. Processing Institute of Mechanical Engineering. Part B Manufacture Engineering. VOL. 213,1999
5 R Kovacevic, H. S Kwak and R S Mohan. Acoustic emission sensing as a tool for understanding the mechanisms of abrasive water jet drilling of difficult-to-machine materials, Processing Institute of Mechanical Engineering. Part B Manufacture Engineering .VOL. 212,1998.
6 M. Hashish. Controlled-depth milling of isogrid structures with AWJs. Journal of Manufacturing Science and Engineering. February 1998,VOL, 120
7 P. Meng. E.S. Gekin, M.C. Leu, F. Li and L. Tismeneskiy. An analytical and experimental study of cleaning with moving waterjets. Journal of Manufacturing Science and Engineering. August 1998, VOL, 120
8 M. C. Len, P. meng, E.S. Geskin and L, Tismeneskiy .Mathematical modeling and experimental verification of stationary waterjet cleaning process. Journal of ManuFacturing Science and Engineering .August 1998, VOL. 120
9 R. E. Williams. Acoustic emission characteristics of abrasive flowmachining. Journal of Manufacturing Science and Engineering .May 1998. VOL. 120
10 Eugene B. Nebeker, Ph.D., and John B. Cramer. Visualization of the central core of high-speed water jets an infrared thechnique.Proceedings of thesecond .U.S. water jet conference. May 1983,90～98
11 Dr.M. Mazurkiewiez. An analysis of one possibility for pulsating a high pressure water jet.Proceedings of the second U.S. water jet conference. May 1983,17～27
12 J.L. Evers, D. Leddingfield and J.Y. Yuh. Dimensionless pipe length analysis for jet modulation systems .Proceedings of the second U.S. water jet conference.May 1983,3～16
13 C.L. Kling, F.G. Hammitt. A photograph study of spark in ducted cavitations bubble collapse. Trans ASME, J Basic Engr, 1972,94(4).
14 V E Johnson, A F Conn, et al, Self-resonating caviating jets . 6th Int Symp on Jet Cutting Technology ,1982.
15 V E Johnson, et al. Cavitating and structured jet for mechanical bits to increase drilling rate. J Ener Eng ,1984
16 Cohen J, Wygnanski I. The evolution of instabilities in the axisymmetric jest. Jet Fluid Mech,1987
17 Dimotakis P E, et al. Structure and dynamics of round turbulent jets. Physics Fluid,1983.
18 Agul J C, Hesselink L. Flow visualization and numerical analysis of acoflowing jet. Jet Fluid Mach,1988
19 (英)狄更逊W等．锥形水射流钻孔．高压水射流，1988(1)28～32
20 (日)中西涉等．高压喷射注浆加固地基RJP工法．喷射技术，1997，1(23)；5～11
21 宋拥政，温效康，梁志强．磨料水射流的切割机制．机械工程学报，1997，6：102～107
22 候健，韩育礼．超高压磨料水射流切割系统试验研究．兵工学报，2000，8，第21卷：253～256
23 遇罗文．高压水射流切割技术和前混切割设备．新技术新工艺，1997，6
24 赵伟、刘晓冰、朱派龙．制造业的一枝奇葩—高压水射流加工技术．机械设计与制造工程，1999，3：1～2
25 史绍熙、林玉静、杨延相，杜青．影响空心旋转液体射流初始阶段运动的无量纲参数的分析．工程热物理学报，2000，7
26 杨延相，林玉静，史绍熙．旋转喷嘴中空旋转射流近区域流动的研究．应用力学学报，2000，6
27 杨延相，林玉静，杜青，史绍熙．空心旋转液体射流初始阶段特性的实验研究．工程热物理学报，2000，6
28 刑茂，赵阳升．高压旋转射流的三维有限元数值模拟研究．太原理工大学学报，2000，9
29 张作龙，梁忠民，高压淹没水射流破岩实验研究．石油矿场机械，2000，5：26～30
30 杨永印，沈忠厚，王瑞和，周卫东．旋转磨料射流破岩钻孔试验研究。石油钻探技术，1999，4
31 步玉环，周卫东，玉瑞和．岩性对旋转射流破岩成孔影响规律的研究，石油钻探技术，2000，8
32 蒋海军，廖荣庆．自激振荡脉冲射流机理探讨．西南石油学院学报，1998，3，第20卷．
33 唐川林，张风华等．它激剪切流动诱发振荡射流的研究．西南石油学院学报，2000，1第22卷：1～4
34 杨建明．电解磨料喷射复合抛光工艺的研究与应用．机械制造，1997，11：14～15
35 (美)J.R.罗思著．工业等离子体工程，第Ⅰ卷：基本原理．北京：科学出版社，1998
36 Tikhomirov R V et al.High -pressure Jet Cutting. New York: ASME 1992
37 余常昭编．紊动射流．北京：高等教育出版社，1993：31～35
38 董允等编著．现代表面工程技术．北京：机械工业出版社，1999，12：43～57
39 建业，徐家文编著．电解加工原理及应用．北京：国防工业出版社，200l，1
40 哈尔滨工业大学刘晋春，赵家齐主编．特种加工．北京：机械工业出版社，1996，5：79～109
41 姬振豫编著．正交设计，天津：天津科技翻译出版公司．1994，4
42 赵文珍主编．材料表面工程导论．西安：西安交通大学出版社．1998，10
43 成建联，宋国英，李福援．磨料水射流抛光工艺的试验研究．2001年中国机械工程学会年会暨第九届全国特种加工学术年会论文集(特种加工技术)．北京：机械工业出版社．2001，11
45 袁哲俊，王先逵主编．精密和超精密加工技术．北京：机械工业出版社．1999，7