气膜屏蔽射流电解加工动态成型及实验研究
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摘要
气膜屏蔽射流电解加工在高压气体作用下,可成形出精度更高、表面质量更好的微结构。为了掌握气膜屏蔽射流电解加工中材料蚀除规律,对加工间隙内多场耦合作用机理进行了理论研究,并基于Fluent和Comsol软件模拟分析了加工间隙内气液分布、电场、流场和温度场等规律,得出工件表面动态成型演变规律并搭建实验设备进行了实验验证。研究结果表明:与传统的射流电解加工相比,气膜屏蔽射流电解加工下加工间隙内电流密度及温度降低、凹坑宽度及深度变小以及深径比提高,实际加工实验与模拟结果相吻合。
The micro-structure with higher precision and better surface quality can be formed by the air-shielding electrochemical micromachining(AS-EMM).In order to master the rule of material erosion during the electrolysis process,the mechanism of multi field coupling in machining gap is studied.The gas-liquid phases,electric field,flow field,temperature field distribution in machining gap are analyzed with Comsol and Fluent softwares,the dynamic forming process of the work piece surface is verified by the experiments.The simulation results show that the current density and the temperature decrease.the width and depth of corrosion pits become smaller and the depth diameter ratio increases which compared with the conventional electrochemical machining.The actual machining experiment coincides with the simulation analysis.
The micro-structure with higher precision and better surface quality can be formed by the air-shielding electrochemical micromachining(AS-EMM).In order to master the rule of material erosion during the electrolysis process,the mechanism of multi field coupling in machining gap is studied.The gas-liquid phases,electric field,flow field,temperature field distribution in machining gap are analyzed with Comsol and Fluent softwares,the dynamic forming process of the work piece surface is verified by the experiments.The simulation results show that the current density and the temperature decrease.the width and depth of corrosion pits become smaller and the depth diameter ratio increases which compared with the conventional electrochemical machining.The actual machining experiment coincides with the simulation analysis.
引文
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[2]WANG Jing,ZHOU Jie,ZHU Shanshan.Friction properties of groove texture on Cr12MoV surface[J].Journal of central south university,2017(2):303-310.
[3]WU B,WU X Y,LEI J G,et al.Study on machining 3Dmicro mould cavities using reciprocating micro ECM with queued foil microelectrodes[J].Journal of materials processing technology,2017,241:120-128.
[4]王贺宾,郭钟宁,罗红平.射流电解加工技术研究现状与展望[J].组合机床与自动化加工技术,2011(4):108-112.
[5]SKRABALAK G,STWORA A.Electrochemical,electrodischarge and electrochemical-discharge hole drilling and surface structuring using batch electrodes[J].Procedia cirp,2016,42:766-771.
[6]WANG M H,ZHU D.Simulation of fabrication for gas turbine blade turbulated cooling hole in ECM based on FEM[J].Journal of materials processing technology,2009,209(4):1747-1751.
[7]SMETS N,DAMME S V,WILDE D D,et al.Time averaged calculations in pulse electrochemical machining,using a strongly non-linear model[J].Journal of applied electrochemistry,2010,40(7):1395-1405.
[8]WU J,WANG H,CHEN X,et al.Study of a novel cathode tool structure for improving heat removal in electrochemical micro-machining[J].Electrochimica acta,2012,75(4):94-100.
[9]DECONINCK D,DAMME S V,ALBU C,et al.Study of the effects of heat removal on the copying accuracy of the electrochemical machining process[J].Electrochimica acta,2011,56(16):5642-5649.
[10]HACKERT-OSCHTZCHEN M,PAUL R,MARTIN A,et al.Study on the dynamic generation of the jet shape in jet electrochemical machining[J].Journal of materials processing technology,2015,223:240-251.
[11]NATSU W,IKEDA T,KUNIEDA M.Generating complicated surface with electrolyte jet machining[J].Precision engineering,2007,31(1):33-39.
[12]黄卫星,李建明,肖泽义.工程流体力学[M].2版.北京:化学工业出版社,2013:281.
[13]李进良,李承曦,胡仁喜.Fluent 6.3流场分析[M].北京:化学工业出版社,2010:4.
[14]THORPE J F,ZERKLE R D.Analytic determination of the equilibrium electrode gap in electrochemical machining[J].International journal of machine tool design&research,1969,9(2):131-144.
[15]钱双庆,张华,鲍凯,等.电解液非线性特性对电解转印加工表面织构定域性影响分析[J].机械设计与制造,2015(10):139-141.
[16]王建业,徐家文.电解加工原理及应用[M].北京:国防工业出版社,2001:205-207.