阶梯异形孔电解加工流场仿真  

Simulation of the Flow Field in Electrochemical Machining of Stepped and Irregularly Shaped Holes

作　　者：李一鑫 祁圣英 刘军团 刘纪玖 陈桦[1,4] 张传运 Li Yixin;Qi Shengying;Liu Juntuan;Liu Jijiu;Chen Hua;Zhang Chuanyun(School of Electromechanical Engineering,Xi’an Technological University,Xi’an 710021,China;Unit 93170 of the People’s Liberation Army of China,Xi’an 710000,China;AECC Aviation Power Co.,Ltd.,Xi’an 710021,China;Shaanxi Provincial Engineering Technology Research Center for Digital Precision Electrochemical Machining,Xi’an 710021,China)

机构地区：[1]西安工业大学机电工程学院,西安710021 [2]中国人民解放军93170部队,西安710000 [3]中国航发动力股份有限公司,西安710021 [4]陕西省数字化精密电解加工工程技术研究中心,西安710021

出　　处：《机电工程技术》2025年第4期112-117,共6页Mechanical & Electrical Engineering Technology

基　　金：太行国家实验室-技术研发项目(cxpt-2022-005)。

摘　　要：针对薄壁阵列阶梯异形孔结构机械加工中存在易变形、效率低、精度难以保证,无法达到预期要求的问题。采用电解加工具有无工具损耗、表面质量好、加工效率高等优势,但其加工精度和加工稳定性受流场影响及其严重。为了提高电解加工阶梯异形孔结构的轮廓精度和加工稳定性,提出了正流式的供液方式和分步式加工方法,利用Comsol仿真软件对流体进行建模并仿真,分析了不同出液口特征(尺寸、数量、排列)对加工间隙内流场均匀性的影响。结果表明:对于第一步阴极样式,采用29个直径为1 mm的出液孔,得到工件表面电解液流速最为均匀,加工区域电解液流速不低于5 m/s;对于第二步阴极样式,采用19个直径为1 mm的出液孔,得到工件表面电解液流速最为均匀,总体电解液流速均大于5 m/s。阴极设计可以满足电解加工过程中对流场分布均匀性和流速大小要求。In the machining of thin-walled array stepped irregular holes,problems such as easy deformation,low efficiency,and difficulty in ensuring precision,which prevent the achievement of the desired requirements,are commonly encountered.Electrolytic machining,with its advantages of no tool wear,good surface quality,and high processing efficiency,has been adopted.However,its processing precision and stability are severely affected by the flow field.In order to address the issues of contour precision and machining stability for stepped irregular hole structures during ECM,a forward flow liquid supply method and a stepwise processing approach are proposed.Fluid modeling and simulation are performed using COMSOL software to analyze the impact of different outlet hole features(size,number,arrangement)on the uniformity of the flow field within the machining gap.The results indicate that for the first step cathode configuration,29 outlet holes with a diameter of 1 mm are used,leading to the most uniform electrolyte flow speed on the workpiece surface,with a flow speed not less than 5 m/s in the machining area.For the second step cathode configuration,19 outlet holes with a diameter of 1 mm are used,resulting in the most uniform electrolyte flow speed on the workpiece surface,with the overall electrolyte flow speed greater than 5 m/s.The cathode design meets the requirements for uniform flow field distribution and flow speed during the electrolytic machining process.

关 键 词：阶梯异形孔 流场仿真 电解加工 流场均匀性 

分 类 号：TG662[金属学及工艺—金属切削加工及机床]