基于微孔电解加工的新型阴极结构
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摘要
为了提高工件材料蚀除的定域性,对裸阴极、侧壁绝缘阴极和缩进阴极进行了研究.以阴阳两极间电解液为研究对象,建立电场模型,通过数值模拟获得加工间隙中电位和电流密度分布,研究阴极结构对微孔进口形状精度的影响.根据模拟结果,分析缩进阴极电解加工微孔时,工艺参数对加工精度和加工效率的影响,优选最佳工艺参数.结果表明,采用优选参数缩进深度50μm,加工电压5V,进给速度3μm/s,能获得良好的加工精度.
In order to improve the material removal localization of workpiece,uninsulated tools,side-insulated tools and retracted tip tools are investigated.Electrolyte between anode and cathode is the main research object in the paper.Computational models of electric field are developed,and the distribution of electric potential and current densities in the machining gap are obtained through numerical simulation method.By the numerical results the effects of using retracted tip tools on entrance quality are researched.Furthermore,effects on machining accuracy and efficiency of using retracted tip tools are analyzed,and optimum parameters are obtained based on the simulation results.Results show that good machining accuracy can be obtained with the optimum parameters that retracted tip depth is 50μm,machining voltage 5V and feed rate 3μm/s.
In order to improve the material removal localization of workpiece,uninsulated tools,side-insulated tools and retracted tip tools are investigated.Electrolyte between anode and cathode is the main research object in the paper.Computational models of electric field are developed,and the distribution of electric potential and current densities in the machining gap are obtained through numerical simulation method.By the numerical results the effects of using retracted tip tools on entrance quality are researched.Furthermore,effects on machining accuracy and efficiency of using retracted tip tools are analyzed,and optimum parameters are obtained based on the simulation results.Results show that good machining accuracy can be obtained with the optimum parameters that retracted tip depth is 50μm,machining voltage 5V and feed rate 3μm/s.
引文
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[2]JIANG Baoyang,LAN Shuhuai,KEVIN W.Modeling and experimental investigation of gas film in micro electrochemical discharge machining process[J].International Journal of Machine Tools&Manufacture,2015,90(1):8-15.
[3]LIAO Yiliang,YE Chang,CHENG G J.A review:Warm laser shock peening and related laser processing technique[J].Optics&Laser Technology,2015,78(1):15-24.
[4]WANG Minghuan,ZHANG Yaobin,HE Zhiwei,et al.Deep micro-hole fabrication in EMM on stainless steel using disk micro-tool assisted by ultrasonic vibration[J].Journal of Materials Processing Technology,2016,229(1):475-483.
[5]SUNDARAM M M,RAJURKAR K P.Electrical and electrochemical processes in intelligent energy field manufacturing[M].Florida:CRC Press,2010:190-191.
[6]RAJURKARA K P,SUNDARAM M M,MALSHE A P.Review of electrochemical and electrodischarge machining[J].Procedia CIRP,2013,6(1):13-26.
[7]WU Jing,WANG Hong,CHEN Xiang,et al.Study of a novel cathode tool structure for improving heat removal in electrochemical micro-machining[J].Electrochimica Acta,2012,75(1):94-100.
[8]KIM Y M,NA C W,LEE Y S,et al.Micro electrochemical machining of 3Dmicro structure using dilute sulfuric acid[J].CIRP Annals-Manufacturing Technology,2005,54(1):191-194.
[9]LIU Yong,ZHU Di,ZENG Yongbin,et al.Development of microelectrodes for electrochemical micromachining[J].International Journal of Advanced Manufacturing Technology,2011,55(1):195-203.
[10]GHOSHAL B,BHATTACHARYYA B.Shape control in micro borehole generation by EMM with the assistance of vibration tool[J].Precision Engineering Eng,2014,38(1):127-137.
[11]LIU Zhuang,LIU Yan,QIU Zhongjun,et al.Effect of tool electrode insulation on electrochemical micro drilling accuracy[J].Nano Technology and Precision Engineering,2009,7(4):355-360.
[12]WANG Wei,ZHU Di,QU Ningsong,et al.Effects of electrode insulation thickness on electrochemical drilling stability and accuracy[J].Transactions of Nanjing University of Aeronautics&Astronautics,2009,26(3):163-169.
[13]WANG Wei,ZHU Di,QU Ningsong,et al.Electrochemical drilling with vacuum extraction of electrolyte[J].Journal of Materials Processing Technology,2010,210(2):238-244.
[14]王建业,徐家文.电解加工原理及应用[M].北京:国防工业出版社,2001:24-26.