工件振动辅助管电极电解加工方孔仿真与试验研究  

Simulation and Experimental Research on Workpiece Vibration-Assisted Electrochemical Machining of Square Holes With Tube Electrode

作　　者：李国军 陈晓磊 叶志森 张永俊[1,2,3] 郭钟宁 LI Guojun;CHEN Xiaolei;YE Zhisen;ZHANG Yongjun;GUO Zhongning(School of Electromechanical Engineering,Guangdong University of Technology,Guangzhou 510006,China;Guangzhou Key Laboratory of Nontraditional Machining and Equipment,Guangzhou 510006,China;State Key Laboratory of Precision Electronic Manufacturing Technology and Equipment,Guangdong University of Technology,Guangzhou 510006,China)

机构地区：[1]广东工业大学机电与工程学院,广州510006 [2]广州市非传统制造技术及装备重点实验室,广州510006 [3]广东工业大学省部共建精密电子制造技术与装备国家重点实验室,广州510006

出　　处：《航空制造技术》2024年第17期83-92,共10页Aeronautical Manufacturing Technology

基　　金：国家自然科学基金面上项目(52075105)。

摘　　要：为解决管电极电解加工方孔过程中因流场分布不均造成加工质量差等问题,提出一种工件振动辅助管电极电解加工方孔的方法。流场仿真结果表明,工件振动辅助电解加工能够在加工间隙内不同位置产生明显的脉动流场,改善加工间隙内的电解液流动状态,有效消除传统电解加工方孔中加工间隙内存在的“死水”区,从而有利于电解产物的排出,提升电解加工的稳定性。同时开展试验研究,结果表明,采用工件振动辅助管电极电解加工可以提升方孔加工的轮廓精度和表面质量,并且采用脉冲电流可以进一步提升方孔的加工质量。最终采用振幅0.04 mm、振频20Hz、脉冲占空比80%、脉冲频率5000 Hz、进给速度1.5 mm/min,加工出平均宽度1.218 mm、宽度标准偏差0.026 mm、侧壁表面粗糙度0.703μm的方孔。In order to solve the problem of poor processing quality caused by uneven distribution of flow field during the process of square holes by electrochemical machining(ECM)with tube electrode,a method of workpiece vibration-assisted ECM of square holes with tube electrode is proposed.The results of flow field simulation indicate that workpiece vibration-assisted ECM can generate obvious pulsating flow fields at different positions within the machining gap,improve the electrolyte flow state within the machining gap and effectively eliminate the stagnant water area within the machining gap in the traditional ECM of square holes,thus facilitating the discharge of electrolytic products and improving the stability of ECM.The experimental researches were also conducted at the same time,and the results show that the use of workpiece vibration-assisted ECM with tube electrode can improve the contour accuracy and surface quality of square holes machining,and the use of pulse current can further improve the quality of square holes machining.Finally,a square hole with an average width of 1.218 mm,width standard deviation of 0.026 mm,side-wall surface roughness of 0.703μm was electrochemically machined by using the amplitude of 0.04 mm,the vibration frequency of 20 Hz,the pulse duty cycle of 80%,the pulse frequency of 5000 Hz and the feed speed of 1.5 mm/min.

关 键 词：方孔 振动辅助 管电极 电解加工(ECM) 仿真 

分 类 号：TG662[金属学及工艺—金属切削加工及机床]