球形阴极数控电解加工关键技术研究
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摘要
当前,由难加工材料制成的复杂型面的零件广泛应用于模具、航空、船舶、汽车、医疗机械等行业中。电解加工技术是利用金属在电解液中发生阳极溶解的原理将零件加工成形的,因工具阴极无损耗、无宏观切削力、适宜加工各种难切削材料制成的零件、表面质量好等优点,在制造业中获得了大量的应用。数控电解加工技术是特种加工领域的研究热点之一,其兼顾了数控技术和电解加工技术的优点,通过程序控制简单形状的阴极相对工件的运动轨迹代替复杂阴极的设计,避免了复杂成形阴极的设计与制造,提高了加工精度和表面质量,广泛应用于难加工材料制成的零件,如叶片、模具等。目前,国内外在数控电解加工技术方面的研究已取得了不小的进展,但在加工精度方面尚不能令大满意。国内的研究主要侧重于利用直线刃阴极对曲面进行粗、精加工,而国外尚未见到对利用球形阴极数控电解加工型面的技术应用于实际生产的报道。考虑到球形阴极的加工部位为球面,可通过数控系统控制阴极相对工件的运动轨迹来加工任意曲面,本文开展适合于一般复杂型面加工的球形阴极数控电解加工关键技术研究,该技术对难加工材料制成零件上复杂型面的加工具有重要的应用意义。
本文的主要内容包括以下几个方面：
1.提出了数控电解加工装置的总体设计方案；通过在一台立铣床的机械本体上设计具有了三个平动轴、一个数控回转轴和一个摆动轴的试验装置,并对装置的关键结构进行了设计计算；设计了性能稳定可靠的球形内喷式旋转阴极和电解液系统。以PMAC (Programmable Multi-Axis Controller)为控制核心开发了基于Visual C++6.0软件平台的数控电解加工机床控制系统软件,该软件具有良好的大际界面,具有初始化、参数设置、手动控制、自动加工、状态显示、模拟量采集等功能,满足了数控电解加工对控制系统的要求,为工艺试验研究的顺利进行奠定了基础。
2.基于计算流体动力学理论,以球形内喷式阴极的电解液流道为研究对象进行电解加工流场的数值模拟研究,建立了电解加工间隙内流场的数值计算模型,分别对流场模型的二维场和三维旋转场进行了数值模拟研究。对初始设计方案的电解液流场进行二维场的数值模拟研究,根据仿真结果得到了流场存在加工间隙内流场存在电解液流速过低、直径收缩处和球面出液口流速变化剧烈的缺陷,考虑在不同初始条件设置下的流场模型,并对比分析得到的仿真结果,表明流场存在同样的缺陷,为解决流场的缺陷,进行阴极的改进设计,对改进设计的方案进行二维场的数值模拟研究,得出的结论包括：1)在阴极的球面中心处增加出液口可解决球面出液口处流速变化剧烈和加工间隙内电解液流速过低的问题；2)将阴极的阶梯形腔改进为锥形腔可解决直径收缩处流速变化剧烈的问题；3)选择了最优设计方案。在二维数值模拟的基础上,对初始方案的电解液流场进行三维旋转场的数值模拟研究,通过分析仿真结果得到了流场存在模型与工件接触表面中心处电解液流速过低、模型剖面的直径收缩处和球面的出液口处流速变化剧烈的缺陷,考虑在不同初始条件设置下的流场模型,并对比分析得到的仿真结果,表明流场存在同样的缺陷,对改进设计的方案进行三维旋转场的数值模拟研究,仿真结果表明二维数值模拟和三维数值模拟的结论一致,均可用于球形阴极电解加工流场的改进设计和特性分析,但三维数值模拟的结果更准确。
3.基于流场数值模拟和阴极改进设计的结果,采用四种方案的阴极以表面粗糙度和切削深度为指标选择工作电压、初始加工间隙、电解液压力、阴极转速、阴极进给速度为主要工艺参数分别进行正交试验,通过对比试验结果,得到采用最优设计方案的阴极加工效果相对最好,验证了流场仿真的准确性,表明将计算流体动力学理论用于球形阴极数控电解加工流场的仿真是可行的,且可以作为理论用于指导阴极的改进设计；进行了球形阴极数控电解加工的单因素工艺试验,得到了单个工艺参数对表面粗糙度和切削深度的影响曲线,总结了工艺规律,为该技术的实际应用奠定了基础。
4.基于电解加工的基础理论,开展了球形阴极数控电解加工成形规律的研究,建立了球形阴极理想加工过程的数学模型,通过MATLAB求解得到了不同工艺参数下加工间隙的变化曲线；提出了基于有限元法的电解加工过程模拟的思路和方法,在ANSYS中建立球形阴极数控电解加工过程的二维电场模型,进行求解计算,得到工件阳极表面不同时刻的电流密度分布和型面变化形状,以过程模拟中的工艺参数进行工艺试验,检测加工型面的尺寸值,并与理论模拟值相比较,试验结果表明,该方法可以满足工程计算的要求,为进一步开展球形阴极数控电解加工过程的研究提供方法和理论依据；在上述分析的基础上,将该理论用于阴极在运动状态下加工间隙内电场的分布研究,得到了工件型面轮廓的变化曲线,分析了加工间隙的变化情况,这对评定一定工艺条件下电解加工工件型面的预测具有重要的意义；通过对比试验结果和计算结果验证了有限元求解模型的准确性,为数控电解加工技术的实际应用奠定了基础。
5.分别进行了球面、圆弧面和叶片型面的加工试验,通过对加工型面的检测数据表明加工的型面基本满足了设计要求,本试验装置可进行曲面的多轴联动电解加工。试验过程中,通过对机床的机械本体、控制系统等各方面进行反复调整、改善,积累了丰富的加工经验,但也遇到了很多阻碍试验顺利进行的问题,需要在今后的研究中不断的解决和完善。
Nowdays parts with complex surface and difficult-to-machine materials are widely used in many fields such as die industry, aviation, and shipbuilding, automobile manufacturing industry, medical devices, and so on. Electrochemical machining (ECM) is an anodic dissolution process to machine workpiece in flowing electrolyte where the shape of cathode (as tool) is copied onto the workpiece (as anode). It has many advantages over traditional machining such as its application regardless of material hardness and strength, no mechanical cutting force, no tool wear, and good surface quality, so ECM is a widely-employed unconventional machining method in manufacturing industry. Numerical control electrochemical machining (NC-ECM) is one of the hot research areas in nontraditional machining, which uses a universal tool-electrode with a simple shape to move along the designed path to obtain the required shapes, and combines the technical characteristics of CNC machining and electrochemical machining. This process not only has the advantage of eliminating the expensive design and manufacture cost for electrodes with complicated shapes, but also has the advantage of increasing machining accuracy and surface quality. NC-ECM is an effective method for machining parts with difficult-to-cut materials and complex geometry, for example, turbine blades, engine casting, dies and molds. The interiorly research focuses on roughing and finishing surface with the linear edge cathode, and the technology using spherical cathode machining surface in actual production haven't been seen in foreign research. Taking into account the spherical processing parts of spherical cathode, the cathode trajectory relative to the workpiece can be controlled by CNC system to machine any surface, so the key technology research of NC-ECM in machining complex surface with spherical cathode is carried out. This technology has important application value on machining complex surface of parts with difficult-to-cut materials, the main contents as follows:
1. The overall design proposal of NC-ECM machine tool is carried out.An ordinary milling machine is transformed with three parallel movement axis and one revolving axis and one oscillating axis, and the calculations are finished in order to design the key structure of machine tool. The inner spraying rotating spherical cathode and electrolyte system are developed and their performance is stabile and reliable to meet the experiment requirements of NC-ECM with spherical cathode. The control system of NC-ECM machine tool based on PMAC (Programmable Multi-Axis Controller) is developed by use of Visual C++6.0software. The software with good man-machine interface has functions such as initialization, parameter settings, manual control, automatic processing, status display, analog quantity collecting and so on. These functions meet the requirements of control system and the foundation is laid for the smooth process of experiments.
2. Based on Computational Fluid Dynamics (CFD) method, the flow field of inner-spraying spherical cathode is used as research object and the research on numerical simulation of flow field is carried out. The numerical calculation model of flow field in the machining gap is established. Two-dimension (2-D) field and three-dimension (3-D) field of flow field model are simulated respectively. The2-D flow field simulation of initial option is carried out. According to the simulation result, there are some defects in the flow field, such as, the lower electrolyte velocity in the inter-electrode gap, the larger range of the velocity at the contraction of flow diameter and the outlet of spherical surface.The2-D flow model are established at the different initial conditions and the simulation results are achieved and analyzed, which show that there are the same defects in the flow field. In order to solve the field defects, the optimal designs of cathode are carried out and the2-D flow field of optimal options is simulated, conclusions as fellows:1) the defects that the larger range of the velocity at the outlet of spherical surface and the lower electrolyte velocity in the inter-electrode gap are solved by means of adding a hole to the center of the spherical surface;2) the defect that the larger range of the velocity at the contraction of flow diameter is solve by means of replace the ladder-shaped cavity with the cross-section of the cone-shaped cavity of the cathode;3) the optimum design is obtained. The3D flow field simulation of initial option is carried out based on the2D flow field simulation. According to the simulation result, there are some defects in the flow field, such as, the lower electrolyte velocity at center of the machining area, the larger range of the velocity at the diameter contraction of the3D model profile and the outlet of spherical surface. The3-D flow model are established at the different initial conditions and the simulation results are achieved and analyzed, which show that there are the same defects in the flow field. In order to solve the field defects, the3-D flow field simulation of optimal options is carried out and the results show that the conclusions obtained separately from2-D and3-D numerical simulation make no difference. It is indicated that both2-D and3-D numerical simulation can used to optimize cathode designs and analyze flow field characteristics, but the3-D numerical simulation results are more accurate.
3. Based on the simulation results of flow field and the optimal design of cathode, four kinds of cathode are used respectively to carry the orthogonal test out. The working voltage, the electrolyte pressure, the initial inter-electrode gap, the cathode rotate-speed, the cathode feed rate are chosen as the technological parameters. The surface roughness and the cutting depth are chosen as the technological indicators. According to the comparisons of experiment results, the machining effects of option three are the best relatively and the numerical simulations are consistent with the experiment results. It is indicated that the computational fluid dynamics (CFD) method can be applied to simulate the flow field, and the optimization design of the cathode can be guided according to the results of simulation. According to the orthogonal test, the experiments are carried out and the curves that the single technological parameter influences on surface roughness and cutting depth are obtained. The technological laws of NC-ECM with spherical cathode are summarized.
4. Based on the basic theory of electrochemical machining, the research on shaping law of NC-ECM with spherical cathode is carried out. The mathematical model of the ideal machining process is established and solved by MATLAB, and the relation curves between different technological parameters and the variation of inter-electrode gap are obtained. In order to solve the difficulty in analyzing the shaping law of NC-ECM with spherical cathode, the method and the thinking of processing simulation are presented based on the finite element method (FEM). The two-dimensional analysis model of the electric field with spherical cathode built in ANSYS software is solved. The current density distribution and surface shape in different time on the anode are obtained. The experiments based on the simulation parameters are carried out, and the dimensions of the machined surface are measured, which are compared with the theoretical values. It is indicated that the simulation method meets the accuracy of the engineering calculations. The method and theory for further in-depth research on the process simulation in NC-ECM with spherical cathode are provided. Based on the above analysis, this method is used to solve the current density distribution in the case of cathode under motion state. The variation curve of workpiece contour is achieved. This method is of great significance for the prediction of workpiece surface under certain technological conditions in NC-ECM. The FEM model is verified by comparisons between experiment results and calculation results. The foundation is laid for the practical application of this technology.
5. The spherical surface, the circular-arc surface and the blade surface are machined and measured respectively. It is showed that these surfaces basically meet the design requirements and the process of electrochemical machining surface with multi-axis linkage can be carried out on this machine tool. The repeated adjustment and improvement are carried out on machine tool, control system and other aspects in the experiment. The problems that impede the experiment will be solved continually in the further research.
本文的主要内容包括以下几个方面：
1.提出了数控电解加工装置的总体设计方案；通过在一台立铣床的机械本体上设计具有了三个平动轴、一个数控回转轴和一个摆动轴的试验装置,并对装置的关键结构进行了设计计算；设计了性能稳定可靠的球形内喷式旋转阴极和电解液系统。以PMAC (Programmable Multi-Axis Controller)为控制核心开发了基于Visual C++6.0软件平台的数控电解加工机床控制系统软件,该软件具有良好的大际界面,具有初始化、参数设置、手动控制、自动加工、状态显示、模拟量采集等功能,满足了数控电解加工对控制系统的要求,为工艺试验研究的顺利进行奠定了基础。
2.基于计算流体动力学理论,以球形内喷式阴极的电解液流道为研究对象进行电解加工流场的数值模拟研究,建立了电解加工间隙内流场的数值计算模型,分别对流场模型的二维场和三维旋转场进行了数值模拟研究。对初始设计方案的电解液流场进行二维场的数值模拟研究,根据仿真结果得到了流场存在加工间隙内流场存在电解液流速过低、直径收缩处和球面出液口流速变化剧烈的缺陷,考虑在不同初始条件设置下的流场模型,并对比分析得到的仿真结果,表明流场存在同样的缺陷,为解决流场的缺陷,进行阴极的改进设计,对改进设计的方案进行二维场的数值模拟研究,得出的结论包括：1)在阴极的球面中心处增加出液口可解决球面出液口处流速变化剧烈和加工间隙内电解液流速过低的问题；2)将阴极的阶梯形腔改进为锥形腔可解决直径收缩处流速变化剧烈的问题；3)选择了最优设计方案。在二维数值模拟的基础上,对初始方案的电解液流场进行三维旋转场的数值模拟研究,通过分析仿真结果得到了流场存在模型与工件接触表面中心处电解液流速过低、模型剖面的直径收缩处和球面的出液口处流速变化剧烈的缺陷,考虑在不同初始条件设置下的流场模型,并对比分析得到的仿真结果,表明流场存在同样的缺陷,对改进设计的方案进行三维旋转场的数值模拟研究,仿真结果表明二维数值模拟和三维数值模拟的结论一致,均可用于球形阴极电解加工流场的改进设计和特性分析,但三维数值模拟的结果更准确。
3.基于流场数值模拟和阴极改进设计的结果,采用四种方案的阴极以表面粗糙度和切削深度为指标选择工作电压、初始加工间隙、电解液压力、阴极转速、阴极进给速度为主要工艺参数分别进行正交试验,通过对比试验结果,得到采用最优设计方案的阴极加工效果相对最好,验证了流场仿真的准确性,表明将计算流体动力学理论用于球形阴极数控电解加工流场的仿真是可行的,且可以作为理论用于指导阴极的改进设计；进行了球形阴极数控电解加工的单因素工艺试验,得到了单个工艺参数对表面粗糙度和切削深度的影响曲线,总结了工艺规律,为该技术的实际应用奠定了基础。
4.基于电解加工的基础理论,开展了球形阴极数控电解加工成形规律的研究,建立了球形阴极理想加工过程的数学模型,通过MATLAB求解得到了不同工艺参数下加工间隙的变化曲线；提出了基于有限元法的电解加工过程模拟的思路和方法,在ANSYS中建立球形阴极数控电解加工过程的二维电场模型,进行求解计算,得到工件阳极表面不同时刻的电流密度分布和型面变化形状,以过程模拟中的工艺参数进行工艺试验,检测加工型面的尺寸值,并与理论模拟值相比较,试验结果表明,该方法可以满足工程计算的要求,为进一步开展球形阴极数控电解加工过程的研究提供方法和理论依据；在上述分析的基础上,将该理论用于阴极在运动状态下加工间隙内电场的分布研究,得到了工件型面轮廓的变化曲线,分析了加工间隙的变化情况,这对评定一定工艺条件下电解加工工件型面的预测具有重要的意义；通过对比试验结果和计算结果验证了有限元求解模型的准确性,为数控电解加工技术的实际应用奠定了基础。
5.分别进行了球面、圆弧面和叶片型面的加工试验,通过对加工型面的检测数据表明加工的型面基本满足了设计要求,本试验装置可进行曲面的多轴联动电解加工。试验过程中,通过对机床的机械本体、控制系统等各方面进行反复调整、改善,积累了丰富的加工经验,但也遇到了很多阻碍试验顺利进行的问题,需要在今后的研究中不断的解决和完善。
Nowdays parts with complex surface and difficult-to-machine materials are widely used in many fields such as die industry, aviation, and shipbuilding, automobile manufacturing industry, medical devices, and so on. Electrochemical machining (ECM) is an anodic dissolution process to machine workpiece in flowing electrolyte where the shape of cathode (as tool) is copied onto the workpiece (as anode). It has many advantages over traditional machining such as its application regardless of material hardness and strength, no mechanical cutting force, no tool wear, and good surface quality, so ECM is a widely-employed unconventional machining method in manufacturing industry. Numerical control electrochemical machining (NC-ECM) is one of the hot research areas in nontraditional machining, which uses a universal tool-electrode with a simple shape to move along the designed path to obtain the required shapes, and combines the technical characteristics of CNC machining and electrochemical machining. This process not only has the advantage of eliminating the expensive design and manufacture cost for electrodes with complicated shapes, but also has the advantage of increasing machining accuracy and surface quality. NC-ECM is an effective method for machining parts with difficult-to-cut materials and complex geometry, for example, turbine blades, engine casting, dies and molds. The interiorly research focuses on roughing and finishing surface with the linear edge cathode, and the technology using spherical cathode machining surface in actual production haven't been seen in foreign research. Taking into account the spherical processing parts of spherical cathode, the cathode trajectory relative to the workpiece can be controlled by CNC system to machine any surface, so the key technology research of NC-ECM in machining complex surface with spherical cathode is carried out. This technology has important application value on machining complex surface of parts with difficult-to-cut materials, the main contents as follows:
1. The overall design proposal of NC-ECM machine tool is carried out.An ordinary milling machine is transformed with three parallel movement axis and one revolving axis and one oscillating axis, and the calculations are finished in order to design the key structure of machine tool. The inner spraying rotating spherical cathode and electrolyte system are developed and their performance is stabile and reliable to meet the experiment requirements of NC-ECM with spherical cathode. The control system of NC-ECM machine tool based on PMAC (Programmable Multi-Axis Controller) is developed by use of Visual C++6.0software. The software with good man-machine interface has functions such as initialization, parameter settings, manual control, automatic processing, status display, analog quantity collecting and so on. These functions meet the requirements of control system and the foundation is laid for the smooth process of experiments.
2. Based on Computational Fluid Dynamics (CFD) method, the flow field of inner-spraying spherical cathode is used as research object and the research on numerical simulation of flow field is carried out. The numerical calculation model of flow field in the machining gap is established. Two-dimension (2-D) field and three-dimension (3-D) field of flow field model are simulated respectively. The2-D flow field simulation of initial option is carried out. According to the simulation result, there are some defects in the flow field, such as, the lower electrolyte velocity in the inter-electrode gap, the larger range of the velocity at the contraction of flow diameter and the outlet of spherical surface.The2-D flow model are established at the different initial conditions and the simulation results are achieved and analyzed, which show that there are the same defects in the flow field. In order to solve the field defects, the optimal designs of cathode are carried out and the2-D flow field of optimal options is simulated, conclusions as fellows:1) the defects that the larger range of the velocity at the outlet of spherical surface and the lower electrolyte velocity in the inter-electrode gap are solved by means of adding a hole to the center of the spherical surface;2) the defect that the larger range of the velocity at the contraction of flow diameter is solve by means of replace the ladder-shaped cavity with the cross-section of the cone-shaped cavity of the cathode;3) the optimum design is obtained. The3D flow field simulation of initial option is carried out based on the2D flow field simulation. According to the simulation result, there are some defects in the flow field, such as, the lower electrolyte velocity at center of the machining area, the larger range of the velocity at the diameter contraction of the3D model profile and the outlet of spherical surface. The3-D flow model are established at the different initial conditions and the simulation results are achieved and analyzed, which show that there are the same defects in the flow field. In order to solve the field defects, the3-D flow field simulation of optimal options is carried out and the results show that the conclusions obtained separately from2-D and3-D numerical simulation make no difference. It is indicated that both2-D and3-D numerical simulation can used to optimize cathode designs and analyze flow field characteristics, but the3-D numerical simulation results are more accurate.
3. Based on the simulation results of flow field and the optimal design of cathode, four kinds of cathode are used respectively to carry the orthogonal test out. The working voltage, the electrolyte pressure, the initial inter-electrode gap, the cathode rotate-speed, the cathode feed rate are chosen as the technological parameters. The surface roughness and the cutting depth are chosen as the technological indicators. According to the comparisons of experiment results, the machining effects of option three are the best relatively and the numerical simulations are consistent with the experiment results. It is indicated that the computational fluid dynamics (CFD) method can be applied to simulate the flow field, and the optimization design of the cathode can be guided according to the results of simulation. According to the orthogonal test, the experiments are carried out and the curves that the single technological parameter influences on surface roughness and cutting depth are obtained. The technological laws of NC-ECM with spherical cathode are summarized.
4. Based on the basic theory of electrochemical machining, the research on shaping law of NC-ECM with spherical cathode is carried out. The mathematical model of the ideal machining process is established and solved by MATLAB, and the relation curves between different technological parameters and the variation of inter-electrode gap are obtained. In order to solve the difficulty in analyzing the shaping law of NC-ECM with spherical cathode, the method and the thinking of processing simulation are presented based on the finite element method (FEM). The two-dimensional analysis model of the electric field with spherical cathode built in ANSYS software is solved. The current density distribution and surface shape in different time on the anode are obtained. The experiments based on the simulation parameters are carried out, and the dimensions of the machined surface are measured, which are compared with the theoretical values. It is indicated that the simulation method meets the accuracy of the engineering calculations. The method and theory for further in-depth research on the process simulation in NC-ECM with spherical cathode are provided. Based on the above analysis, this method is used to solve the current density distribution in the case of cathode under motion state. The variation curve of workpiece contour is achieved. This method is of great significance for the prediction of workpiece surface under certain technological conditions in NC-ECM. The FEM model is verified by comparisons between experiment results and calculation results. The foundation is laid for the practical application of this technology.
5. The spherical surface, the circular-arc surface and the blade surface are machined and measured respectively. It is showed that these surfaces basically meet the design requirements and the process of electrochemical machining surface with multi-axis linkage can be carried out on this machine tool. The repeated adjustment and improvement are carried out on machine tool, control system and other aspects in the experiment. The problems that impede the experiment will be solved continually in the further research.
引文
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