微凹坑超声电解滚蚀加工间隙多物理场特性及成形规律  

Multi-physical Field in IEG and Micro-dimple Forming in Ultrasonic Rolling Electrochemical Micromachining

作　　者：王明环[1,2] 王嘉杰 童文俊 陈侠 许雪峰[1,2] 王芯蒂 WANG Minghuan;WANG Jiajie;TONG Wenjun;CHEN Xia;XU Xuefeng;WANG Xindi(College of Mechanical Engineering, Zhejiang University of Technology, Hangzhou 310014, Zhejiang, China;Key Laboratory of Special Purpose Equipment and Advanced Processing Technology of Ministry of Education, Zhejiang University of Technology, Hangzhou 310014, Zhejiang, China)

机构地区：[1]浙江工业大学机械工程学院,浙江杭州310014 [2]浙江工业大学,特种装备制造与先进加工技术教育部重点实验室,浙江杭州310014

出　　处：《兵工学报》2020年第4期783-791,共9页Acta Armamentarii

基　　金：国家自然科学基金项目(51975532、51475428);浙江省自然科学基金项目(LY19E050007)。

摘　　要：针对径向超声能场滚蚀微细电解加工(RUR-EMM)间隙物理场变化复杂、能观性较差等问题,基于数值模拟方法,对加工中间隙多物理场耦合作用及变化规律进行研究。建立加工间隙内电场、两相流场、温度场、声场等多场耦合理论模型,通过数值仿真分析得出多场耦合相互影响变化规律、多场耦合下凹坑成型规律。研究结果表明:在振动频率20 kHz、振幅10μm、加工间隙50μm、工具阴极旋转角速度0.6°/s、电解液电导率7.9 S/m工况下,超声能场激励微细电解加工中,间隙内电解液周期性流入、流出加工区;电流密度随振动周期发生周期性变化;电解液温度随超声激励与电化学反应的综合作用升高;与滚蚀微细电解加工相比,RUR-EMM间隙内温度上升3.63%、电流密度提高1.45倍,间隙脉动流场有效促进了产物排出,RUR-EMM凹坑深度最大增加14.21%;微凹坑加工试验结果验证了理论模型的正确性,仿真与实际加工试验深度误差在17.07%以内。For the complex physical change and poor observability of the radial ultrasound rolling eletrochemical micromachining(RUR-EMM)gap physics field,the coupling effect of multi-physical field in machining gap is studied based on the numerical simulation method.A multi-field coupling theory model of electric field,two-phase flow field,temperature field and sound field in machining gap is established.Based on the proposed model,the variation rule of multi-field coupling interaction and the forming rule of micro dimple under multi-field coupling are obtained by numerical simulation method.Results show that the electrolyte in the gap flows into and out of the machining zone with vibration frequency of 20 kHz,amplitude of 10μm,machining gap of 50μm,cathode rotating angular velocity of 0.6°/s,and electrode conductivity of 7.9 S/m.The current density periodically changes with vibration cycle,and the temperature of electrolyte increases with the combined action of ultrasonic vibration and electrochemical reaction.Compared with rolling electrochemical micromachining(R-EMM),the gap temperature and current density of RUR-EMM are increased by 3.63%and 1.45 times,respectively,and the dimple depth of RUR-EMM is increased by 14.21%.This is because the pulsating flow field in the gap promotes the discharge of products effectively.The experimental results of micro-dimple machining verify the correctness of the theoretical model.The error between the simulated and experimental machining depths is less than 17.07%.

关 键 词：微细电解加工 微凹坑 超声振动 滚蚀加工 多物理场 

分 类 号：TG662[金属学及工艺—金属切削加工及机床]