旋转超声电解复合加工小孔流场仿真
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摘要
为解决电解加工深小孔中电解液难以进入加工区和电解产物难以排出的问题,构建了内喷式旋转超声电解复合加工装置,进行了电解加工、旋转电解加工和旋转超声电解复合加工小孔的对比试验。试验结果表明,阴极旋转能明显提高孔的圆度,旋转超声电解复合加工具有最大的平均加工电流,所加工孔的直径、深度都为三者中最大,表明其材料去除率是最大的。在此基础上,利用有限元ANSYS CFX软件,建立了气液两相流三维气穴模型,分析了阴极旋转和阴极高频振动对电解加工流场、电场的影响。仿真结果表明:阴极旋转使得气泡在阴极表面聚集,不利于气泡的排出,阴极振动加速了电解液的运动,有利于气泡的排出,因此具有最大的材料去除率。
In order to solve the difficulties to update the electrolyte and discharge the products in the electrochemical machining(ECM)for deep-small holes,the internal rotary ultrasonic electrolytic composite machining device was constructed,and the comparative experiments of ECM,rotary electrochemical machining(RECM)and RUECM were carried out.The results show that the roundness of holes is improved by the rotation of cathode and the average current is the largest in the RUECM,thus the diameter and the depth of the holes machined by RUECM are the largest,which indicates that the material removal rate(MRR)is the greatest,too.Based on those,the effects of the rotation and vibration of cathode on the flow field and electric field were analyzed by ANSYS CFX with the three-dimensional two-phase flow cavitation model.The simulation results show that when cathode rotates,the air bubbles are gathered on the cathode surfaced,which is not conducive to the discharge of air bubbles;when cathode vibrates,the motion of electrolyte is accelerated,which is conducive to the discharge of air bubbles,therefore,it has the greatest MRR in RUECM,which provides a basis for future researches.
In order to solve the difficulties to update the electrolyte and discharge the products in the electrochemical machining(ECM)for deep-small holes,the internal rotary ultrasonic electrolytic composite machining device was constructed,and the comparative experiments of ECM,rotary electrochemical machining(RECM)and RUECM were carried out.The results show that the roundness of holes is improved by the rotation of cathode and the average current is the largest in the RUECM,thus the diameter and the depth of the holes machined by RUECM are the largest,which indicates that the material removal rate(MRR)is the greatest,too.Based on those,the effects of the rotation and vibration of cathode on the flow field and electric field were analyzed by ANSYS CFX with the three-dimensional two-phase flow cavitation model.The simulation results show that when cathode rotates,the air bubbles are gathered on the cathode surfaced,which is not conducive to the discharge of air bubbles;when cathode vibrates,the motion of electrolyte is accelerated,which is conducive to the discharge of air bubbles,therefore,it has the greatest MRR in RUECM,which provides a basis for future researches.
引文
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[17]王明环,刘望生,彭伟.螺旋微小深孔电解加工间隙多相流场特性及实验研究[J].兵工学报,2013,34(6):748-753.Wang Minghuan,Liu Wangsheng,Peng Wei.Research on Flow-field Characteristics of Gap Multiphase Flow and Experiment of Electrochemical Machining of Spiral Deep Small Hole[J].Ordnance Technology,2013,34(6):748-753.
[18]王超.卧式油气三相分离器的流场研究[D].长春:吉林大学,2011.
[19]谢汉龙,赵新宇,张炯明.ANSYS CFX流体分析及仿真[M].北京:电子工业出版社,2011.
[20]Baburaj M.CFD Analysis of Flow Pattern in Electrochemical Machining for L-shapedtool[D].Rourkela:National Institute of Technology,2012.
[21]Rajurkar K P,Zhu D,McGeough J A,et al.New Development in Electrochemical Machining[J].Ann.CIRP,1999,48(2):567-579.
[2]Ruszaj A,Zybura M,Zurek R,et al.Some Aspects of the Electrochemical Machining Process Supported by Electrode Ultrasonic Vibrations Optimization[J].J.Engineering Manufacture,2003,217:1365-1371.
[3]Hewidy M S,Ebeid S J,El-Taweel T A,et al.Modeling the Performance of ECM Assisted by Low Frequency Vibration[J].Journal of Materials Processing Technology,2007,189:466-472.
[4]Bhattacharyya B,Malapati M,Munda J,et al.Influence of Tool Vibration on Machining Performance in Electrochemical Micro-machining of Copper[J].International Journal of Machine Tools&Manufacture,2007,47:335-342.
[5]李红英,云乃彰,朱永伟.超声电解复合微细加工硬质合金试验研究[J].航空制造技术,2009(1):78-82.Li Hongying,Yun Naizhang,Zhu Yongwei.Experimental Investigation of Combined Ultrasonic and Electrochemical Micro-machining of Cemented Carbide[J].Aeronautical Manufacturing Technology,2009(1):78-92.
[6]朱永伟,王占和,李红英,等.电解复合超声频振动微细加工机理与试验研究[J].中国机械工程,2008,19(15):1786-1792.Zhu Yongwei,Wang Zhanghe,Li Hongying,et al.Machining Mechanism and Test Study on MicroMachining of ECM Combined Ultrasonic Vibration[J].China Mechanical Engineering,2008,19(15):1786-1792.
[7]王艺钢.超声辅助电解加工微细三维结试验研究[D].淄博:山东理工大学,2013.
[8]朱永伟,王占和,云乃彰.超声电解复合微细加工装置与试验研究[J].机械科学与技术,2008,27(8):986-991.Zhu Yongwei,Wang Zhanhe,Yun Naizhang.An ECM Combined Ultrasonic Vibration Micro-machining Device and Its Test Study[J].Mechanical Science and Technology for Aerospace Engineering,2008,27(8):986-991.
[9]赵志强.超声扰动电解液微细电解加工机理及实验的基础研究[D].青岛:青岛科技大学,2014.
[10]Sebastian S.Research on Ultrasonically Assisted Electrochemical Machining Process[J].International Journal of Advanled Manufalturing Technology,2011,52(5):565-574
[11]徐家文,云乃彰,王建业,等.电化学加工技术原理工艺及应用[M].北京:国防工业出版社,2008.
[12]Liu Zexiang,Kang Min.The Analysis of Small Holes by the Rotary Combined Ultrasonic and Electrochemical Machining[J].Journal of the Chinese Society of Mechanical Engineers,2014,35(3):197-204.
[13]李志永,朱荻.基于叶片电解加工电场和流场特性的阴极设计和工艺试验研究[J].中国机械工程,2006,17(14):1463-1467.Li Zhiyong,Zhu Di.Cathode Design and Experimental Study on Electrochemical Machining of Turbine Blades Based on Characteristics of Electric Field and Liquid Field[J].China Mechanical Engineering,2006,;17(14):1463-1467.
[14]徐正扬,朱荻,王蕾,等.三头进给电解加工叶片流场特性[J].机械工程学报,2008,44(4):189-194.Xu Zhengyang,Zhu Di,Wang Lei,et al.Character of Flow Field on Turbine Blade with 3-Electrode Feeding Method in Electrochemical Machining[J].Chinese Journal of Mechanical Engineering,2008,44(4):189-194.
[15]林仲茂.超声变幅杆的原理和设计[M].北京:科学出版社,1987.
[16]彭耀,陈凤,宋耀祖,等.电场作用下单气泡行为的数值模拟[J].清华大学学报(自然科学版),2008,48(2):294-297.Peng Yao,Chen Feng,Song Yaozu,et al.Numerical Simulations of Single Bubble Behavior in DC Electric Fields[J].J.Tsinghua Univ.(Sci.&Tech.),2008,48(2):294-297.
[17]王明环,刘望生,彭伟.螺旋微小深孔电解加工间隙多相流场特性及实验研究[J].兵工学报,2013,34(6):748-753.Wang Minghuan,Liu Wangsheng,Peng Wei.Research on Flow-field Characteristics of Gap Multiphase Flow and Experiment of Electrochemical Machining of Spiral Deep Small Hole[J].Ordnance Technology,2013,34(6):748-753.
[18]王超.卧式油气三相分离器的流场研究[D].长春:吉林大学,2011.
[19]谢汉龙,赵新宇,张炯明.ANSYS CFX流体分析及仿真[M].北京:电子工业出版社,2011.
[20]Baburaj M.CFD Analysis of Flow Pattern in Electrochemical Machining for L-shapedtool[D].Rourkela:National Institute of Technology,2012.
[21]Rajurkar K P,Zhu D,McGeough J A,et al.New Development in Electrochemical Machining[J].Ann.CIRP,1999,48(2):567-579.