大深径比小孔激光与管电极电解同步复合加工技术  

Fabrication of High-Aspect-Ratio Small Holes by Laser and Shaped Tube Electrochemical Machining

作　　者：王玉峰 杨勇[1] 刘云峰[2] 张文武[1] WANG Yufeng;YANG Yong;LIU Yunfeng;ZHANG Wenwu(Ningbo Institute of Materials Technology and Engineering,Chinese Academy of Sciences,Ningbo 315201,China;Zhejiang University of Technology,Hangzhou 310014,China)

机构地区：[1]中国科学院宁波材料技术与工程研究所,宁波315201 [2]浙江工业大学,杭州310014

出　　处：《航空制造技术》2025年第1期64-72,共9页Aeronautical Manufacturing Technology

基　　金：国家自然科学基金(51905525);浙江省自然科学基金重大项目(LD22E050013);宁波市重点研发计划(2023Z028)。

摘　　要：针对难加工材料大深径比小孔低损伤高效精密加工难题,提出了激光与管电极电解同步复合加工方法(Laser-STEM)。利用内全反射效应将激光高效传导至大深度加工区,通过中心激光加工和边缘电解加工同步进行,实现大深径比小孔高表面质量、高效率精密加工。研究了激光与复合工具电极的耦合方法及机理,实现激光高效率稳定传导。通过观测Laser-STEM复合加工过程中试验现象和加工间隙演化,结合加工轮廓检测,证明了小孔高效精密成形的可行性。建立了复合加工电流信号变化与加工状态的映射关系。在钛合金、高温合金上高效加工出直径1.25 mm,深径比达125∶1,无再铸层、无微裂纹的小孔。所提出的复合加工方法可用于航空发动机和燃气轮机关键部件高表面质量、大深径比微小孔的高效精密加工。To stress the issues of fabrication high-aspect-ratio small holes with low damage,high efficiency and high precision,laser and shaped tube electrochemical hybrid machining(Laser-STEM)has been proposed.In Laser-STEM,the laser is guided to the machining zone by internal total reflection through the hybrid tool electrode,in which the materials could be removed by laser processing at the center and electrochemical machining at the surrounding area synchronously,thus high-aspect-ratio small holes with high surface quality could be processed.The coupling method and mechanisms between the laser and hybrid tool electrode were studied.A high efficiency and stable laser transmission has been achieved.Feasibility of processing small holes with high efficiency and precision by Laser-STEM has been proven by observing the experimental phenomena and variation of the machining gap.Moreover,the relationship between the change of hybrid machining current signal and the machining state was established.Micro holes with a diameter of 1.25 mm,a depthdiameter ratio of 125:1,without recast layer and microcracks were processed on titanium alloy and nickel-based superalloy.The proposed hybrid processing method can be used for efficient and precise machining of micro holes with high surface quality and large aspect ratio for key components of aero-engines and gas turbines.

关 键 词：激光加工 电解加工 复合加工 大深径比小孔 低损伤深小孔 

分 类 号：V26[航空宇航科学与技术—航空宇航制造工程]