CN104227160A - Constant-flow tube electrode electrolytic machining method - Google Patents
Constant-flow tube electrode electrolytic machining method Download PDFInfo
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- CN104227160A CN104227160A CN201410477621.9A CN201410477621A CN104227160A CN 104227160 A CN104227160 A CN 104227160A CN 201410477621 A CN201410477621 A CN 201410477621A CN 104227160 A CN104227160 A CN 104227160A
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Abstract
The invention relates to a constant-flow tube electrode electrolytic machining method and belongs to the technical field of electrolytic machining. The constant-flow tube electrode electrolytic machining method comprises the following steps of 1, supplying constant-flow electrolyte to a processing region by use of a metering pump; 2, monitoring an outlet pressure value of the metering pump by use of a first pressure sensor arranged at the outlet of the metering pump, monitoring the outlet electrolyte pressure value of a tube electrode by use of a second pressure sensor arranged on a cathode clamp cavity; 3, monitoring a processing current of a main loop by use of a hall current sensor; 4, performing tube electrode electrolytic machining; 5, monitoring the electrolyte pressure and the processing current in real time, and judging that a hole is through when observing that the electrolyte pressure and the processing current are reduced suddenly, wherein the distance between the tube electrode and the bottom surface of a workpiece at the moment is delta; 6, continuing to feed the tube electrode for a distance of 2delta, and stopping processing. The method and the device provided by the invention has great significance in promoting discharge of electrolytic products and Joule heat in deep small-hole tube electrode electrolytic machining and ensuring the hole outlet precision.
Description
Art
Constant flow pipe electrode electrochemical machining method of the present invention, belongs to technical field of electrolysis processing.
Background technology
According to statistics, hole machined accounts for 1/3 of machining total amount, accounts for 1/4 of machining total time.Wherein the hole of nearly 5% is the Fine and Deep Hole on difficult-to-machine material.Such as, Fine and Deep Hole on hollow cooling turbine bucket, stator blade, atomizer.The traditional mechanical drilling process of this some holes has been difficult to processing, and tool loss is large; Adopt Laser Processing to there is surface remelting layer problem, require that secondary operations must be carried out to hole in very harsh aero-engine field at Surface Quality; Comparatively Laser Processing is low to adopt spark machined efficiency, and there is remelted layer problem equally; Adopt Electrolyzed Processing crudy to significantly improve, also can adopt array electrode processing group hole, improve working (machining) efficiency.
When pipe electrode Electrolyzed Processing (Shaped tube electrochemical drilling is called for short STED) is carried out, electrolyte flows out from hollow metal pipe (pipe or shape tube) high speed, is full of whole machining gap.Tool cathode feeding, workpiece anode dissolves and forms the pass consistent with metal tube cross section gradually under electrochemical reaction effect, and electrolyte takes product, Joule heat out of processing district simultaneously.This technique has and does not limit by workpiece material mechanics, mechanical performance, and the features such as crudy is good, and instrument is lossless, have important application in industries such as Aero-Space, automobile, Making mold.
Pipe electrode electrochemical Machining Technology is aircraft engine division department of General Electric is a kind of electrolysis cheesing techniques that the aperture processing difficult problem solving superalloy material in aero-engine proposes.Adopt mass fraction 10%-25% HNO
3or H
2sO
4as electrolyte, adopt the titanium pipe scribbling insulating barrier to carry out electrolysis perforation processing as electrode simultaneously.Discharge difficult problem for solving insoluble electrolysate, they employ acidic electrolysis bath, and now electrolysate is ionic state, avoid the spark discharge because precipitate bulk causes and short circuit phenomenon.Because acid working solution also exists environment unfriendly, plant maintenance requires the problems such as high, and Chinese scholars begins one's study neutral salt solution pipe electrode Electrolyzed Processing.
After adopting neutral salt solution, electrolysate will form precipitation owing to dissolving, and be present in machining gap, and the stability of impact processing, has done a large amount of research work both at home and abroad to promote that elaboration products are discharged.
Nebraska,USA university Rajurkar K.P. professor and Polish Polytechnics Kozak J. etc., propose to adopt the pulse power to replace dc source to carry out pipe electrode Electrolyzed Processing (20% NaNO
3solution), the electrolysate in gap can be able to abundant discharge in interpulse period, obtains stable process.The essence of the method is the growing amount by reducing insoluble product in the unit interval, improves product expulsion efficiency, but for deep hole machining, the method DeGrain, and greatly reduce working (machining) efficiency.
Taiwan National Yunlin University of Science and Technology Guo Jia really waits electrolyte stream flowing mode (20% NaNO
3solution) improve, invent coaxial spray suction method.Unique cathod system structure, sealing surface of the work electrolyte flow region, suction pump provides especially power to take the electrolyte containing electrolysate in processing district in time away.The method cathod system complex structure, can not be generalized to large scale array group hole machined occasion.
Nanjing Aero-Space University professor Zhu Di proposes to adopt the mode such as electrode obit, drawing-in type reflux to carry out pipe electrode Electrolyzed Processing (16% NaNO
3solution).The translation of electrode cycle will improve anodic solution uniformity, and sidewall spacers periodically expansion reduces, and inner formation low frequency pulsating pressure, improves product and discharge effect; Drawing-in type reflux pipe electrode electrochemical Machining Technology, by changing electrolyte flow direction, processing district, electrolyte, from the backflow of pipe electrode endoporus, avoids the impact of electrolysate on electrolytic conductivity.Under high rotating speed, the kinematic accuracy of orbital head is not high, and processing stability is poor, and the asymmetrical stress distribution of tube wall surrounding easily causes electrode vibration, produces the groove dissolving of ring week; Drawing-in type reflux due to produce vacuum pressure reduction limited, deep hole machining is had little significance.
Egyptian Menoufia University Hewidy M.S., Polish Polytechnics Kozak J. etc. propose electrode low-frequency vibration electrochemical Machining Technology.The vibration of tool-electrode will be fluctuated by mineralization pressure in gap, and electrolyte renewal rate is accelerated, and the discharge of elaboration products is more convenient.This apparatus structure is complicated, and the size in gap back and forth change can cause that electrolyte refluxes, gap flow field is disorderly, and processing stability is deteriorated; The reciprocal low-frequency vibration amplitude of tool-electrode of the method, much smaller than the working depth in hole, discharges low effort for deep hole machining product.
Above-mentioned research work all adopts electrolyte constant pressure to process, and along with the increase of working depth increases along journey pressure drop, flow of electrolyte reduces, flow velocity reduces, and electrolysate, Joule heat is discharged slack-off, have impact on processing stability.
In addition, existing pipe electrode Electrolyzed Processing, the independent change according to electric current judges whether hole machines usually.But due to the existence of dispersion corrosion during the break-through of hole, judge to bring difficulty to curent change, be difficult to obtain desirable hole exits precision.
Summary of the invention
The present invention is intended to improve in Fine and Deep Hole neutral salt solution pipe electrode Electrolyzed Processing to be increased along journey pressure drop increase with hole depth, and electrolyte flow rate reduces the problem causing the discharge of elaboration products, Joule heat not smooth; And the existence improved due to dispersion corrosion, cannot comparatively accurately judge hole exits position separately through curent change, cause the situation that hole exits precision is not high.Proposing one can make processing stablize, and improves the constant flow pipe electrode electrochemical machining method of hole exits precision.
A kind of constant flow pipe electrode electrochemical machining method, adopts pipe electrode Electrolyzed Processing hole, it is characterized in that comprising the following steps: (1), utilize measuring pump to provide the electrolyte of constant flow rate to machining area; (2) the first pressure sensor monitoring measuring pump outlet pressure numerical value being arranged on measuring pump exit, is utilized; Utilize the second pressure sensor monitoring pipe electrode exit electrolyte pressure numerical value being arranged on cathode fixture cavity place; (3) Hall current sensor, is utilized to monitor major loop processing electric current (4), carry out pipe electrode Electrolyzed Processing; (5), Real-Time Monitoring electrolyte pressure, processing electric current, observe electrolyte pressure and processing electric current sudden change reduce time, represent hole break-through.Now recording pipe electrode apart from workpiece bottom distance is
δ; (6), pipe electrode continues feeding 2
δafter distance, stop processing.
The device of the constant flow pipe electrode electrochemical machining method described in realization, comprise power supply, electrolyte circulation system, electrolytic machine tool, the control system of electrolytic machine tool, cathod system, the control system of above-mentioned electrolytic machine tool comprises motion control card, data collecting card, current sensor, industrial computer; Above-mentioned electrolyte circulation system comprises liquid reserve tank, valve, measuring pump, Pressure gauge, flowmeter, work box successively; It is characterized in that: replace conventional constant voltage pump with measuring pump, to machining area conveying constant flow electrolyte; Also comprise the pressure sensor be connected on pipe electrode installation cavity, for real-time accurate measurements outlet pressure, combine with current sensor, judge the accurate location of pipe electrode during the break-through of hole.
During constant electrolyte pressure pipe electrode Electrolyzed Processing, especially when carrying out deep hole machining, along with little hole depth increases electrolyte along journey pressure drop, causing flow of electrolyte to reduce gradually, flow velocity declines.Electrolyte cannot upgrade in time, and electrolysate and Joule heat will be caused to get rid of difficulty.The present invention utilizes measuring pump that the electrolyte of constant flow rate is delivered to machining area, ensure in process along with little hole depth increases, flow of electrolyte, flow velocity remain unchanged, thus electrolyte can be upgraded in time all the time, improve the situation of electrolysate and Joule heat discharge difficulty.
In addition, utilize pressure sensor to monitor the pressure of electrolyte outlet in real time, observe the change of electrolyte pressure numerical value.When employing constant flow adds man-hour, along with the increase of working depth, electrolyte pressure raises gradually.During the break-through of hole, can pressure release be produced, make electrolyte pressure now have unexpected decline.Now pipe electrode end face distance workpiece bottom
δ, this distance is machining gap.According to simulation result, in pipe electrode Electrolyzed Processing, when pipe electrode be fed to exceed workpiece bottom distance be greater than machining gap value position time, hole sidewall current density is less than 10A/cm
2, hole is shaped completely.Therefore, after the break-through of hole, pipe electrode still needs to continue feeding 2
δdistance is until processing stops.If negative electrode feeding distance is too small, hole exits can not be shaped completely; If feeding distance is excessive, then outlet can be made in horn-like in the face of the dispersion corrosion of workpiece bottom due to cathode terminal.
The method constant flow realizes simple, need not change original frock clamp, machine tool structure, uses measuring pump to provide the electrolyte of constant flow rate, and at electrolyte output setting pressure sensor.
Accompanying drawing explanation
Fig. 1 is product distribution schematic diagram in Fine and Deep Hole pipe electrode interelectrode gap;
Fig. 2 is pipe electrode Electrolyzed Processing cathode site schematic diagram;
Fig. 3 is constant flow pipe electrode electrochemical machining system schematic diagram;
Fig. 4 is machining process simulating model;
Fig. 5 is that process current density is along sidewall distribution map.
Wherein label title: 1, electrolyte liquid reserve tank, 2, valve, 3, measuring pump, the 4, first pressure sensor, 5, flowmeter, 6, Pressure gauge, 7, tool holder, 8, main shaft proceeding equipment, 9, machine body, 10, pipe electrode, the 11, second pressure sensor, 12, XY motion workbench, 13, workpiece, 14, work box, 15, electrolyte, 16, motion control card, 17, the program control voltage stabilizing pulse power, 18, current sensor, 19, data collecting card, 20, industrial computer.
Detailed description of the invention
In Fig. 1, electrolyte enters pipe electrode 9 with certain flow, injects machining gap at a high speed, takes away electrolysate and Joule heat, completes interpolar electrolyte and upgrades.By pipe electrode 9 lateral wall insulation, Electrolyzed Processing locality can be improved.
Fig. 2, (a) is pipe electrode Electrolyzed Processing hole break-through cathode site schematic diagram, and during constant flow pipe electrode Electrolyzed Processing hole break-through as shown in (a), pressure sensor numerical value reduces suddenly, now tool cathode tip to face distance workpiece bottom
δ.B () is that pipe electrode Electrolyzed Processing hole machined terminates cathode site schematic diagram; As shown in (b), negative electrode continues feeding 2
δ, hole is shaped completely, process finishing.
In constant flow pipe electrode electrochemical machining system shown in Fig. 3, the pulse power 17, main shaft proceeding equipment 8, electrode holder 7 and machine body 9, work box 13 and workbench 12 form electrolytic machine tool hardware system; Motion control card 16, data collecting card 19, current sensor 18, pressure sensor 4, industrial computer 20 and line related constitute electrolytic machine tool control system; Electrolysis liquid reserve tank 1, valve 2, measuring pump 3, work box 14 and associated pipe composition electrolyte circulation system.Measuring pump by electrolyte with constant flow delivery to machining area.Electrolyte pressure is monitored in real time via pressure sensor, and by pressure value over time images outputting on industrial computer, in order to observation monitoring process.
Composition graphs 1, Fig. 2, Fig. 3 illustrate implementation process of the present invention:
1, with reference to figure 3, workpiece 12 is positioned by XY platform 11 after installing.During tool setting, apply test voltage by power supply 17 at two interpolars, the feeding of main shaft 8 low speed, the change of current signal is measured by current sensor 18, and industrial computer 20 pairs of signals carry out detection and complete tool setting, and set initial manufacture gap width.
2, with reference to figure 1, Fig. 2, Fig. 3, when Electrolyzed Processing starts, start measuring pump 3, by electrolyte with constant flow delivery to pipe electrode fixture cavity, high speed inject machining gap; Power supply 17 output voltage; Main shaft 8 drives tool-electrode 10 feeding, carries out Fine and Deep Hole pipe electrode Electrolyzed Processing.In process, the second pressure sensor 11 is monitoring electrolyte pressure numerical value in real time, and current sensor 18 shows current values, and flowmeter 5 shows real-time traffic numerical value, in order to observe monitoring process.When the sudden change of electrolyte pressure numerical value reduces, pipe electrode distance workpiece bottom
δ, be machining gap value.Negative electrode continues feeding 2
δafter, terminate processing.
Below, composition graphs 4, Fig. 5, the present invention will be described further:
Fig. 4 utilizes COMSOL Multiphysics software to emulate set up model to the Electric Field Distribution situation in pipe electrode electrochemical machining process.Utilize steady-state current module to adopt axial symmetry mode to carry out modeling, pipe electrode external diameter is 0.8mm, internal diameter 0.6mm, and machining gap value is 0.15mm.End face and inwall are ground connection, and anode workpiece potential value is set to 10V, and other boundary conditions are insulation.
Fig. 5, be in simulation result process current density along the distribution situation of workpiece sidewall.Can find out that the processing electric current density that workpiece sidewall is on negative electrode end face reduces along with the increase of z coordinate value, when z coordinate value is 0.15, current density has been less than 10A/cm^2, can think no longer to process herein, and hole is shaped completely.Therefore, after the break-through of hole, pipe electrode still needs to continue feeding 2
δdistance is until processing stops.If negative electrode feeding distance is too small, hole exits can not be shaped completely; If feeding distance is excessive, then outlet can be made in horn-like in the face of the dispersion corrosion of workpiece bottom due to cathode terminal.
Claims (1)
1. a constant flow pipe electrode electrochemical machining method, adopts pipe electrode Electrolyzed Processing hole, it is characterized in that comprising the following steps:
(1) measuring pump, is utilized to provide the electrolyte of constant flow rate to machining area;
(2) the first pressure sensor monitoring measuring pump outlet pressure numerical value being arranged on measuring pump exit, is utilized; Utilize the second pressure sensor monitoring pipe electrode exit electrolyte pressure numerical value being arranged on cathode fixture cavity place;
(3) Hall current sensor, is utilized to monitor major loop processing electric current;
(4), pipe electrode Electrolyzed Processing is carried out;
(5), Real-Time Monitoring electrolyte pressure, processing electric current, observe electrolyte pressure and processing electric current sudden change reduce time, represent hole break-through; Now recording pipe electrode apart from workpiece bottom distance is
δ;
(6), pipe electrode continues feeding 2
δafter distance, stop processing.
Priority Applications (1)
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|---|---|---|---|
| CN201410477621.9A CN104227160A (en) | 2014-09-18 | 2014-09-18 | Constant-flow tube electrode electrolytic machining method |
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|---|---|---|---|
| CN201410477621.9A CN104227160A (en) | 2014-09-18 | 2014-09-18 | Constant-flow tube electrode electrolytic machining method |
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Cited By (8)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN106964856A (en) * | 2017-04-26 | 2017-07-21 | 常州工学院 | It is a kind of to prevent the method and device of Electrolyzed Processing hole break-through short circuit |
| CN109420811A (en) * | 2017-08-31 | 2019-03-05 | 深圳市水佳鑫科技有限公司 | Hard metal boring method and equipment |
| CN109554739A (en) * | 2018-12-20 | 2019-04-02 | 山东大学 | A kind of scan-type micro arc oxidation treatment device and method |
| CN109848492A (en) * | 2019-02-20 | 2019-06-07 | 安徽理工大学 | The self-priming reflux electrochemical machining method of pipe electrode high speed rotation |
| CN110514091A (en) * | 2019-08-30 | 2019-11-29 | 中国航发动力股份有限公司 | A kind of design method of precision ECM processing cathode site consistency |
| CN112823992A (en) * | 2019-11-19 | 2021-05-21 | 中国科学院宁波材料技术与工程研究所 | Laser and electrolyte combined processing method and processing device thereof |
| CN113405443A (en) * | 2021-06-15 | 2021-09-17 | 南京航空航天大学 | Soft intelligent hole detection device and method applied to aero-engine |
| CN114945439A (en) * | 2020-01-28 | 2022-08-26 | 株式会社牧野铣床制作所 | Fine hole electric discharge machine |
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| JPH0740146A (en) * | 1993-01-19 | 1995-02-10 | Corning Inc | Method for electro-chemical machining of shaped pipe |
| WO2001043909A1 (en) * | 1999-12-16 | 2001-06-21 | MTU MOTOREN- UND TURBINEN-UNION MüNCHEN GMBH | Electrode for electrochemically fineboring workpieces and method for producing the same |
| CN102198549A (en) * | 2011-05-20 | 2011-09-28 | 南京航空航天大学 | Electrochemical machining method and device for pulsating flow field tube electrode |
| CN103611994A (en) * | 2013-11-21 | 2014-03-05 | 南京航空航天大学 | Complex-surface recast-layer-free single/group-hole multi-station electric spark-electrolytic machine tool |
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Patent Citations (4)
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| JPH0740146A (en) * | 1993-01-19 | 1995-02-10 | Corning Inc | Method for electro-chemical machining of shaped pipe |
| WO2001043909A1 (en) * | 1999-12-16 | 2001-06-21 | MTU MOTOREN- UND TURBINEN-UNION MüNCHEN GMBH | Electrode for electrochemically fineboring workpieces and method for producing the same |
| CN102198549A (en) * | 2011-05-20 | 2011-09-28 | 南京航空航天大学 | Electrochemical machining method and device for pulsating flow field tube electrode |
| CN103611994A (en) * | 2013-11-21 | 2014-03-05 | 南京航空航天大学 | Complex-surface recast-layer-free single/group-hole multi-station electric spark-electrolytic machine tool |
Cited By (10)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN106964856A (en) * | 2017-04-26 | 2017-07-21 | 常州工学院 | It is a kind of to prevent the method and device of Electrolyzed Processing hole break-through short circuit |
| CN106964856B (en) * | 2017-04-26 | 2018-11-23 | 常州工学院 | A kind of method and device preventing the break-through short circuit of Electrolyzed Processing hole |
| CN109420811A (en) * | 2017-08-31 | 2019-03-05 | 深圳市水佳鑫科技有限公司 | Hard metal boring method and equipment |
| CN109554739A (en) * | 2018-12-20 | 2019-04-02 | 山东大学 | A kind of scan-type micro arc oxidation treatment device and method |
| CN109848492A (en) * | 2019-02-20 | 2019-06-07 | 安徽理工大学 | The self-priming reflux electrochemical machining method of pipe electrode high speed rotation |
| CN110514091A (en) * | 2019-08-30 | 2019-11-29 | 中国航发动力股份有限公司 | A kind of design method of precision ECM processing cathode site consistency |
| CN112823992A (en) * | 2019-11-19 | 2021-05-21 | 中国科学院宁波材料技术与工程研究所 | Laser and electrolyte combined processing method and processing device thereof |
| CN114945439A (en) * | 2020-01-28 | 2022-08-26 | 株式会社牧野铣床制作所 | Fine hole electric discharge machine |
| CN113405443A (en) * | 2021-06-15 | 2021-09-17 | 南京航空航天大学 | Soft intelligent hole detection device and method applied to aero-engine |
| CN113405443B (en) * | 2021-06-15 | 2022-07-01 | 南京航空航天大学 | Soft intelligent hole detection device and method applied to aero-engine |
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