微幅往复走丝微细电解线切割试验研究

 微细电解线切割是一种新型的微细加工技术,适合高精度金属窄缝、窄槽等微细结构的加工,由于加工间隙内电解产物排出困难,容易影响加工精度。为了提高产物排出效率,提出线电极微幅往复走丝促进加工间隙内电解产物排出的方法,改善了加工稳定性,提高了加工精度和加工效率。建立了间隙内电解产物排出效率对加工精度、加工速度影响的数学模型,分析了线电极走丝速度和走丝幅值对间隙内电解产物排出和电解液更新的影响。通过试验研究了线电极的走丝速度和走丝幅值对加工精度和加工效率的影响规律,采用优化参数在厚度为80 μm的钴基弹性合金上进行微槽结构加工,底面粗糙度约为0.45 μm,倒角半径小于8 μm。结果表明线电极轴向微幅往复走丝可以有效地提高加工质量和加工效率。     

微尺度线电极电解加工

微尺度线电极电解是近期出现的一种新加工方法,采用钨丝作为线电极,在加工过程中电极无损耗,通过控制工具电极轨迹可实现微细结构加工。建立了微尺度线电极电解加工模型;通过微尺度线电极叠加微幅振动,促进了加工间隙中电解液更新;针对加工电压、脉冲宽度、脉冲周期和加工速度等影响微尺度线电极电解加工精度的因素进行了参数对比试验,并对加工参数进行了分析和优化。采用电化学腐蚀原理进行微米尺度线电极的在线制作,在线制得直径10 μm和2 μm的线电极,实现了切缝宽度为20 μm以下的复杂微细结构以及切缝宽度为8 μm以下的微螺旋结构。     

群孔管电极电解加工均流设计及其试验研究

 为提高群孔电解加工的稳定性和成形精度,对群孔管电极电解加工(ECD)的分流腔流场进行了建模分析。通过对分流腔进行数值求解,研究了分流腔电解液的分布规律,并分析得到了影响电解液分流均匀度的主?问?分流腔直径),进而对其进行了优化设计。基于该优化设计并结合试验得到了适合正流群孔电解加工的分流均匀度系数和相应的尺寸系数。采用优化的分流腔参数和加工参数进行试验,得到了尺寸精度较好的长排孔结构,孔间距5 mm,孔径为(1.03±0.03)mm,其加工过程稳定,无短路现象。通过优化分流腔结构可以提高其分流均匀度,从而使电解孔加工的稳定性显著增加,加工精度提高。     

钛合金径向超声振动铣削表面粗糙度研究

为提高钛合金零件加工质量,设计了径向超声振动辅助铣削试验装置,研究了切削速度、切削深度、进给速度和超声振动幅值对钛合金零件表面粗糙度的影响规律.试验结果表明,与普通铣削相比,径向超声振动铣削后工件上的刀痕更加平整、分布更加均匀,材料去除更彻底,有效减少了由于钛合金切屑粘刀造成的表面划痕和积屑瘤等现象.在不同的切削参数下,径向超声振动铣削均可以改善钛合金零件的表面粗糙度,这一点在低速切削时更为明显,而超声振动幅值过大或过小都会影响加工质量.对加工系统的切削力进行了分析,发现超声振动辅助铣削时系统的切削力明显减小,有助于提高加工系统的稳定性,从而能够获得较好的表面质量.     

钛合金小余量叶片脉冲电流电解加工

脉冲电流电解加工可以改善流场,提高加工稳定性,有利于进行小间隙加工,从而提高加工精度。本文介绍了脉冲电流电解加工钛合金小余量叶片的情况,并且取得了较好的效果。     

三元流闭式叶轮组合电加工技术研究Ⅲ——数控电火花精加工关键技术

 数控电火花（NC-EDM）精加工,是三元流闭式叶轮组合电加工的最终加工工序,是决定三元流闭式叶轮整体制造精度的关键工序。本文专题介绍了其主要关键技术,包括工具电极、运动轨迹以及工装夹具设计。基于关键技术的解决,进行了某型三元流闭式叶轮组合电加工工艺试验,试制加工了合格零件。研究结果表明,数控电解(NC-ECM)预加工可充分发挥电解加工高效率的特点,而数控电火花精加工又可保证对复杂整体构件加工需要万无一失的高可靠性和高精度的要求。两者结合,可以实现高效、精密、可靠、整体制造三元流闭式叶轮的目标。     

脉动态电解加工

电解加工在航空航天装备的核心部件制造中起到了重要作用。为了满足这些高科技产品的发展需求,它的加工精度需要进一步提高。电解加工过程中产生的氢气、温升及去除物,会显著影响加工间隙中电解液电导率的分布,并降低加工精度。脉动态电解加工将工具振动与脉冲给电优化耦合,改变了间隙状态,提高了精度和稳定性。拷贝式、旋印式、削边电极线切割式等3种脉动态电解加工形式分别对应叶片类、机匣类、榫槽类结构的加工表现出很好的工艺效果。     

基于精密电解工艺的叶片进排气边形状控制方法

针对高温合金复杂曲面叶片进排气边尺寸和形状的高精度要求,开展了精密电解加工试验研究。结果表明,利用振动进给电解机床与优化电极设计方法可以有效提高电解加工叶片进排气边尺寸形状精度。使用电导率85~90m S/cm,温度25℃的Na NO3电解液,叶盆和叶背电极振幅0.4mm,振频40Hz可加工出中心型面进气边形状满足设计要求,排气边接近设计要求的试件。在此基础上,探索采用振动光饰工艺作为精密电解加工技术的辅助手段解决叶片进排气边形状控制难题的方法。     

深小孔电解加工

本文扼要分析了深小孔电解加工的各主要工艺因素(如电解液、电极、脉冲加工电流、电极导向、多孔同时加工和进给速度等)及其加工过程中的相应措施,从而保证了深小孔的加工质量并提高了生产效率.     

钛合金水中电火花加工的研究

在宇航工业中,经常遇到有小孔、特形孔及复杂形状的钛合金零件需要电火花加工。为了研究钛合金电火花加工性能,我们曾进行了TC4钛合金电火花加工性探讨试验,用晶体管脉冲电源,在煤油介质中进行了紫铜、黄铜、石墨电极、正负极性及有无高压等等的加工,结果均不理想,加工后在钛合金工件表面上产生凸泡,在电极表面上出现一个凹坑。用小能量加工时也同样产生,加工越深或者面积越大凸坑越大,电极损坏越严重。 通过试验发现:在蒸馏水(电阻率为375千欧·厘米)中用紫铜电极、负电极、具有270伏高压回路加工较为理想。为了使钛合金在蒸馏水中电火花加工更好的应用,因而进行了本课题的试验研究,现将结果介绍如下。     

Cathode design investigation based on iterative correction of predicted profile errors in electrochemical machining of compressor blades

Electrochemical machining (ECM) is an effective and economical manufacturing method for machining hard-to-cut metal materials that are often used in the aerospace field. Cathode design is very complicated in ECM and is a core problem influencing machining accuracy, especially for complex profiles such as compressor blades in aero engines. A new cathode design method based on iterative correction of predicted profile errors in blade ECM is proposed in this paper. A math-ematical model is first built according to the ECM shaping law, and a simulation is then carried out using ANSYS software. A dynamic forming process is obtained and machining gap distributions at different stages are analyzed. Additionally, the simulation deviation between the prediction profile and model is improved by the new method through correcting the initial cathode profile. Further-more, validation experiments are conducted using cathodes designed before and after the simulation correction. Machining accuracy for the optimal cathode is improved markedly compared with that for the initial cathode. The experimental results illustrate the suitability of the new method and that it can also be applied to other complex engine components such as diffusers.     

Electrochemical machining of complex components of aero-engines: Developments,trends, and technological advances

Because of several advantages, such as no tool wear, independence on the mechanical properties of the material, and high machining efficiency, electrochemical machining (ECM) has become a viable method for machining components in numerous industrial applications, particularly in the manufacture of typical aero-engine components with complex structures fabricated from materials that are difficult to cut. This paper highlights the current developments, new trends, and technological advances of key factors of ECM, such as electrochemical dissolution characteristics of novel difficult to cut materials which are often used in aero-engine, numerical simulation of electrochemical process, design for the complex profile and structure of cathode tool, flow field simulation and design for uniform electrolyte flow, and innovation of electrochemical machining or hybrid methods which reflect the state of the art in academic and industrial research on electrochemical machining in aero-engine manufacturing.     

Electrochemical trepanning with uniform electrolyte flow around the entire blade profile

In the traditional machining process for diffusers, blades are easily deformed, and methods suffer from high tool wear and low efficiency. Electrochemical machining(ECM) possesses unique advantages when applied to these difficult-to-machine materials. In the ECM process, theflow field plays a crucial role. Here, an electrolyte flow mode that supplies uniform flow around the entire blade profile was adopted for electrochemical trepanning of diffusers. Various flow rates were employed to obtain the optimal flow field. Simulations were conducted using ANSYS software, and results indicated that increasing the flow rate substantially afforded a more uniform flowfield. A series of experiments was then performed, and results revealed that increasing the flow rate greatly improved both the machining efficiency and the surface quality of the diffusers. The maximum feeding rate of the cathode reached 4 mm/min, the blade taper of the concave part decreased to 0.02, and the blade roughness was reduced to 1.216 lm. The results of this study demonstrated the high feasibility of this method and its potential for machining other complex components for engineering applications.     

Analysis and control of inter-electrode gap during leveling process in counter-rotating electrochemical machining

The inter-electrode gap (IEG) is an essential parameter for the anode shaping process in electrochemical machining (ECM) and directly affects the machining accuracy. In this paper, the IEG during the leveling process of an oval anode workpiece in counter-rotating ECM (CRECM) is investigated. The variation of the minimum IEG is analyzed theoretically, and the results indicate that rather than reaching equilibrium, the minimum IEG in CRECM expands constantly when a constant feed speed is used for the cathode tool. This IEG expansion leads to a poor localization effect and has an adverse influence on the roundness of the machined workpiece. To maintain a small constant IEG in CRECM, a variable feed speed is used for the cathode based on a fitted equation. The theoretical results show that the minimum IEG can be controlled at a small value by using an accelerated feed speed. Experiments have been conducted using a specific experimental apparatus in which the cathode tool is designed as a combined structure of two sectors and a thin sheet. By detecting the machining currents flowing through the minimum IEG, how the latter varies is obtained indirectly. The results indicate that using an accelerated feed speed is effective for controlling the IEG, thereby improving the roundness of the machined workpiece.     

Simulation and experimental investigation on a dynamic lateral flow mode in trepanning electrochemical machining

An appropriate flow mode of electrolyte has a positive effect on process efficiency, surface roughness, and machining accuracy in the electrochemical machining(ECM) process. In this study, a new dynamic lateral flow mode, in which the electrolyte flows from the leading edge to the trailing edge, was proposed in trepanning ECM of a diffuser. Then a numerical model of the channel was set up and simulated by using computational fluid dynamics software. The result showed that the distribution of the flow field was comparatively uniform in the inter-electrode gap. Furthermore, a fixture was designed to realize this new flow mode and then corresponding experiments were carried out. The experimental results illustrated that the feeding rate of the cathode reached 2 mm/min, the best taper angle was about 0.4°, and the best surface roughness was up to Ra= 0.115 lm. It reflects that this flow mode is suitable and effective, and can also be applied to machining other complex structures in trepanning ECM.     

Convex shaping process simulation during counter-rotating electrochemical machining by using the finite element method

In counter-rotating electrochemical machining(CRECM), a revolving cathode tool with hollow windows of various shapes is used to fabricate convex structures on a revolving part. During this process, the anode workpiece and the cathode tool rotate relative to each other at the same rotation speed. In contrast to the conventional schemes of ECM machining with linear motion of a block tool electrode, this scheme of ECM is unique, and has not been adequately studied yet. In this paper, the finite element method(FEM) is used to simulate the anode shaping process during CRECM, and the simulation process which involves a meshing model, a moving boundary,and a simulation algorithm is described. The simulated anode profiles of the convex structure at different processing times show that the CRECM process can be used to fabricate convex structures of various shapes with different heights. Besides, the variation of the inter-electrode gap indicates that this process can also reach a relative equilibrium state like that in conventional ECM. A rectangular convex and a circular convex are successfully fabricated on revolving parts. The experimental results indicate relatively good agreement with the simulation results. The proposed simulation process is valid for convex shaping prediction and feasibility studies as well.     

精密复杂曲面零件多轴数控加工技术研究进展

多轴数控（CNC）加工是现代工业中的标志性加工技术,在能源、动力、国防、运载工具、航空航天等制造领域的关键零部件加工中占据着主导地位。随着这些领域中高端装备性能要求越来越高,涌现出一大批加工难度大、性能指标要求苛刻的精密复杂曲面零件,其加工已由以往单纯的形位精度要求,跃升为形位与性能指标并重的高性能加工要求,给传统的复杂曲面零件数控加工技术带来了严峻挑战。针对精密复杂曲面零件形位精度保证、加工效率提升及动态切削过程可控等关键技术问题,从多轴数控加工的高效加工路径设计、进给率规划以及加工动力学分析等方面,详细论述相关加工技术的研究现状、存在的难点和核心问题,指出可行的解决途径、突破方向和未来的发展趋势,为实现复杂曲面零件的高性能数控加工提供参考和依据。     

钛合金整体闭式叶轮刀具的研究

本文结合某型号钛合金整体闭式叶轮的研制过程,针对钛合金材料的加工特性,和整体闭式叶轮的结构特点,采用科学的正交实验方法和先进的加工方法来优化刀具几何参数及提高刀具刚性,使数控铣削刀具达到理想的切削性能和耐用度,从而大幅提高加工效率和质量,降低生产成本。     

电解加工发动机叶片阴极进给方向的优化

 超薄扭曲叶片由于叶型超薄、型面复杂、精度要求高, 目前主要以电解加工作为首选加工工艺。以某新型发动机叶片为研究对象, 对电解加工阴极的进给方向、毛坯装夹位置做了优化选择并对叶片型面采样点的法线方向与阴极斜向进给方向的夹角分布做了详细的阐述, 为阴极型面的设计打下了坚实的基础。     

Trajectory control strategy of cathodes in blisk electrochemical machining

A turbine blisk, which combines blades and a disk together, is one of the most important components of an aero engine. In the process of blisk electrochemical machining (ECM), the sheet cathode, which is usually used as a tool electrode, has a complicated structure. In addition to that, the channel between the adjacent blades is narrow and twisted, so interference is apt to happen when the sheet cathode feeds into the channel. Therefore, it is important to choose suitable trajectory control strategy. In this paper, a new trajectory control strategy of the sheet cathode is presented and corresponding simulation analysis is conducted on the basis of an actual blisk model. The simulation results demonstrate that the sheet cathode can feed into the channel by a spatial line trajectory without interference. Moreover, the verification experiments are carried out according to the simulation. The experimental results show that the cathode can move into the channel without interference. It is verified that the new trajectory control strategy is correct and can be used in the blisk ECM process successfully.