抽吸电极电解加工微小孔加工工艺研究  

Research on Electrochemical Machining Technology of Small-hole Using Suction Electrode

作　　者：闫英 孙国荣 董晋彤 周平[1] YAN Ying;SUN Guo-rong;DONG Jin-tong;ZHOU Ping(Key Laboratory for Precision and Non-traditional Machining Technology of Ministry of Education,Dalian University of Technology,Dalian 116024)

机构地区：[1]大连理工大学精密与特种加工教育部重点实验室,大连116024

出　　处：《机械工程学报》2022年第5期268-277,共10页Journal of Mechanical Engineering

基　　金：国家自然科学基金(51975094,51875078,51991373);中央高校基本科研业务费专项资金(DUT20LAB108,DUT20ZD216)资助项目。

摘　　要：航空发动机中的微小孔电解加工的入口杂散腐蚀影响着零部件的疲劳强度,针对电解加工微小孔时入口形貌不理想的难题,利用抽吸电极电解加工方法,有效降低了高温合金上微小孔入口的杂散腐蚀。通过多物理场耦合模型分析了电解加工过程中的电场、流场分布情况和轮廓成型过程,与相同参数下管电极电解加工对比,同时研究加工过程中的供给流量与抽吸压力的大小对入口形貌的影响,并优化了仿真参数,进而指导加工工艺。仿真与试验结果表明:采用合适的抽吸电极结构和加工工艺参数,电解加工的入口杂散腐蚀区域可明显减小甚至消失,可以有效提高加工定域性;在其他参数不变的情况下,采用1.5 mL/min的供给流量、27 mL/min的回收流量时,加工过程稳定无短路,获得的入口形貌无杂散腐蚀。研究结果对进一步了解抽吸电极电解加工的原理以及提高高温合金小孔加工质量均具有重要意义。The stray corrosion at the entrance of the electrochemical machining of small-hole in the aero-engine seriously affects the fatigue strength of the parts. Because the morphology of the electrochemical machining entrance is not ideal, the stray corrosion of the micro-hole entrance is reduced by suction electrode processing. In this work, the electric field, flow field distribution, and contour forming process in the electrochemical machining process are analyzed by a multi-physical field model. The simulation results and the experimental results are compared with each other under the same parameters to optimize the processing parameters. The influence of supply flow rate and suction pressure on the inlet morphology is analyzed. The simulation and experimental results show that the region of low current density region at the entrance of suction electrode electrochemical machining can be significantly reduced,which improves the locality of the machining. If the supply flow rate is 1.5 ml/min and the reflow rate is 27 ml/min, the best inlet morphology without stray corrosion will be obtained with stable processing without the short circuit. This work is of great significance for further understanding the principle of electrochemical machining of suction electrodes and improving the quality of small holes in superalloys.

关 键 词：微小孔 抽吸电极 电解加工 气液两相流 多物理场耦合 

分 类 号：TG662[金属学及工艺—金属切削加工及机床]