菱形孔电解加工数值模拟及试验研究
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摘要
以菱形孔加工为研究对象设计了菱形工具阴极圆形通液槽,模拟了菱形孔电解加工电场、流场变化情况,得到了菱形孔加工区域内电流密度、流速、压力、气泡率、加工轮廓的分布情况,分析了菱形孔棱角位置容易形成圆角的原因。研究开展了菱形孔电解加工试验,得到的加工试样与理论分析基本吻合,同时探讨了不同圆形通液槽横截面面积对加工平均电流、入口侧面间隙、底部侧面间隙的影响规律,其结果可为提高菱形孔电解加工精度提供依据和参考。
Taking the diamond hole as the research object,the circular flow passage groove of diamond tool cathode was designed,and the changes of electric field and flow field in electrochemical machining of diamond hole were simulated numerically. The distribution of current density,flow velocity,pressure,bubble rate and processing contour in the diamond hole processing area were obtained,and the reason why the corner position of diamond hole is easy to form a round corner was analyzed. The electrochemical machining test of diamond hole was carried out,and the sample of diamond hole was obtained,which basically coincided with the theoretical analysis. Furthermore,the influence of the cross section area of different circular liquid passage tank on the machining current,side clearance of inlet and bottom were discussed. The results can provide basis and reference for improving the accuracy of electrochemical machining for diamond hole.
Taking the diamond hole as the research object,the circular flow passage groove of diamond tool cathode was designed,and the changes of electric field and flow field in electrochemical machining of diamond hole were simulated numerically. The distribution of current density,flow velocity,pressure,bubble rate and processing contour in the diamond hole processing area were obtained,and the reason why the corner position of diamond hole is easy to form a round corner was analyzed. The electrochemical machining test of diamond hole was carried out,and the sample of diamond hole was obtained,which basically coincided with the theoretical analysis. Furthermore,the influence of the cross section area of different circular liquid passage tank on the machining current,side clearance of inlet and bottom were discussed. The results can provide basis and reference for improving the accuracy of electrochemical machining for diamond hole.
引文
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[2]江伟,张晔,陈远龙,等.高频窄脉冲电解加工叶片的多场耦合仿真研究[J].航空制造技术,2016(18):69-74.
[3]江伟,干为民,张晔.叶片脉冲电解加工过程的多场耦合模拟[J].电加工与模具,2015(2):24-28.
[4]张美丽,朱荻,徐正扬.基于ANSYS分析的钛合金电解辅助阳极设计[J].机械科学与技术,2007,26(9):1141-1143.
[5]吴小龙,徐正扬,陈学振.钛合金型腔电解加工流场设计与试验[C]//第15届全国特种加工学术会议论文集.南京,2013:95-100.
[6]房晓龙,曲宁松,李寒松,等.电极内孔结构对钛合金方孔电解加工的影响[J].华南理工大学学报(自然科学版),2013,41(9):137-142.
[7] BORTELS L,PURCAR M,BOSSCHE B V D,et al. A user-friendly simulation software tool for 3D ECM[J].Journal of Materials Processing Technology,2004,149(1-3):486-492.
[8] KLOCKE F,ZEIS M,HARST S,et al. Modeling and simulation of the electrochemical machining(ECM)material removal process for the manufacture of aero engine components[J]. Procedia CIRP,2013(8):265-270.
[9] GUO Cheng,QIAN Jun,REYNAERTS D. Electrochemical machining with scanning micro electrochemical flow cell[J]. Journal of Materials Processing Technology,2017(247):171-183.
[10] RAJURKAR K P,ZHU D. Improvement of electrochemical machining accuracy by using orbital electrode movement[J]. CIRP Annals,1999,48(1):139-142.
[11] PACZKOWSKI T,ZDROJEWSKI J. Monitoring and control of the electrochemical machining process under the conditions of a vibrating tool electrode[J]. Journal of Materials Processing Technology,2017(244):204-214.
[12] MINAZETDINOV N M. Cavitation flow of an ideal incompressible fluid in the electrochemical machining of metals[J]. Journal of Applied Mathematics and Mechanic,2017,81(1):29-35.
[13] ZHAO Jianshe,ZHANG Xiangli,YANG Zhenwen,et al.Experimental research on the optimization of precision electrochemical machining feed mode of diamond-hole grille[J]. The International Journal of Advanced Manufacturing Technology,2017,91(1-4):147-153.
[14] ZHAO Jianshe,WANG Feng,ZHANG Xiangli,et al.Experimental research on improving ECM accuracy and stability for diamond-hole grilles[J]. Procedia CIRP,2018(68):684-689.
[15] LAIO Y S,WU L C,PENG W Y. A study to improve drilling quality of electrochemical discharge machining(ECDM)process[J]. Procedia CIRP,2013(6):609-614.