CN110893493B - Electrolytic electric spark composite leveling tool and method for manufacturing rough metal surface by additive manufacturing - Google Patents
Electrolytic electric spark composite leveling tool and method for manufacturing rough metal surface by additive manufacturing Download PDFInfo
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- 238000010892 electric spark Methods 0.000 title claims abstract description 72
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 58
- 239000002184 metal Substances 0.000 title claims abstract description 56
- 229910052751 metal Inorganic materials 0.000 title claims abstract description 56
- 239000000654 additive Substances 0.000 title claims abstract description 53
- 230000000996 additive effect Effects 0.000 title claims abstract description 53
- 238000000034 method Methods 0.000 title claims abstract description 29
- 239000002131 composite material Substances 0.000 title claims abstract description 16
- 238000003754 machining Methods 0.000 claims abstract description 93
- 238000005868 electrolysis reaction Methods 0.000 claims abstract description 45
- 239000003792 electrolyte Substances 0.000 claims description 24
- 238000005507 spraying Methods 0.000 claims description 9
- 230000002068 genetic effect Effects 0.000 claims description 8
- 239000012530 fluid Substances 0.000 claims description 6
- 239000007788 liquid Substances 0.000 claims description 4
- 239000007921 spray Substances 0.000 claims description 4
- 150000001875 compounds Chemical class 0.000 claims description 2
- 238000009826 distribution Methods 0.000 claims description 2
- 230000005684 electric field Effects 0.000 claims description 2
- 238000012545 processing Methods 0.000 abstract description 12
- 239000000463 material Substances 0.000 abstract description 8
- 238000007599 discharging Methods 0.000 abstract 1
- 238000009499 grossing Methods 0.000 abstract 1
- 238000005498 polishing Methods 0.000 abstract 1
- 238000005516 engineering process Methods 0.000 description 11
- 238000010586 diagram Methods 0.000 description 5
- 239000000243 solution Substances 0.000 description 4
- 238000007639 printing Methods 0.000 description 3
- 238000011160 research Methods 0.000 description 3
- 238000010276 construction Methods 0.000 description 2
- 238000013461 design Methods 0.000 description 2
- 238000000110 selective laser sintering Methods 0.000 description 2
- 230000009286 beneficial effect Effects 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
- 238000005253 cladding Methods 0.000 description 1
- 238000011161 development Methods 0.000 description 1
- 238000004090 dissolution Methods 0.000 description 1
- 238000010894 electron beam technology Methods 0.000 description 1
- 230000003628 erosive effect Effects 0.000 description 1
- 239000002360 explosive Substances 0.000 description 1
- 238000009776 industrial production Methods 0.000 description 1
- 238000003475 lamination Methods 0.000 description 1
- 238000004372 laser cladding Methods 0.000 description 1
- 230000004807 localization Effects 0.000 description 1
- 230000007774 longterm Effects 0.000 description 1
- 238000002844 melting Methods 0.000 description 1
- 230000008018 melting Effects 0.000 description 1
- 239000007769 metal material Substances 0.000 description 1
- 238000000465 moulding Methods 0.000 description 1
- 239000004033 plastic Substances 0.000 description 1
- 229920003023 plastic Polymers 0.000 description 1
- 239000012255 powdered metal Substances 0.000 description 1
- 239000012266 salt solution Substances 0.000 description 1
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23H—WORKING OF METAL BY THE ACTION OF A HIGH CONCENTRATION OF ELECTRIC CURRENT ON A WORKPIECE USING AN ELECTRODE WHICH TAKES THE PLACE OF A TOOL; SUCH WORKING COMBINED WITH OTHER FORMS OF WORKING OF METAL
- B23H5/00—Combined machining
- B23H5/02—Electrical discharge machining combined with electrochemical machining
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Abstract
The invention relates to an electrolytic electric spark composite leveling tool and method for manufacturing a rough metal surface in an additive manufacturing mode, and belongs to the technical field of electric spark electrolytic machining. The method carries out continuous leveling processing on the extremely unsmooth surface of the additive manufacturing metal through an electrolysis-electric spark-electrolysis composite process new method. The method comprises the steps of firstly preliminarily leveling the extreme high points on the surface of a workpiece through the tubular electrode extreme gap jet flow electrolytic machining, then rapidly discharging and further leveling the higher points through an electric spark electrode, and finally further electrolytically machining and smoothing the rough and leveled surface processed by the electric spark through the tubular electrode, thereby achieving the purpose of efficiently leveling and polishing the rough surface of the metal manufactured by material increase. The invention can efficiently level and smooth the surface of the metal manufactured by the additive through electrolysis-electric spark-electrolysis continuous processing, and has important significance for improving the processing efficiency of the metal manufactured by the additive.
Description
Technical Field
The invention relates to an electrolytic electric spark composite leveling tool and method for manufacturing a rough metal surface in an additive manufacturing mode, and belongs to the field of electric spark electrolytic machining.
Background
Additive manufacturing is a technique for building objects by layer-by-layer printing using bondable materials, such as powdered metals or plastics, based on digital model files. Additive manufacturing is typically achieved using digital technology material printers. The method is often used for manufacturing models in the fields of mold manufacturing, industrial design and the like, and is gradually used for directly manufacturing some products, and parts printed by the technology are already available. The technology has applications in jewelry, footwear, industrial design, construction, engineering and construction, automotive, aerospace, dental and medical industries, education, geographic information systems, civil engineering, firearms, and other fields.
With the requirements of scientific and technological development and popularization and application, more and more metal part additive manufacturing technologies are developed. The process suitable for the metal material in the additive manufacturing process mainly comprises a Selective Laser Sintering (SLS) technology, a Selective Laser Melting (SLM) technology, a Selective Laser Cladding (SLC) technology, a lamination molding (LOM) technology and an electron beam cladding technology. In recent years, a lot of research has been conducted on metal printing materials, printing process conditions, auxiliary treatment, and the like in the additive manufacturing technology, metal additive manufacturing has already entered into market manufacturing, and a commercial metal additive manufacturing machine has been made available. A process suitable for metal additive manufacturing is briefly described, discussing various process features, issues, and research advances.
The principle of electric spark machining is a method for removing the material of a metal workpiece based on the phenomenon of electric erosion during pulsed spark discharge between a tool and the workpiece, thereby achieving the machining requirements predetermined for the shape, size and surface quality of the part. Because the material is removed mainly by explosive heat energy generated by instant pulse discharge, the surface after electric spark machining is often rough, and the machined surface has a heat affected zone and a recast layer.
The electrolytic machining uses a hollow metal tube as an electrolyte nozzle, and forms a machined surface by controlling the numerical control track of the tool cathode in a milling-like manner. During the machining process, the current mainly reaches the surface of the workpiece from the inner side wall of the nozzle through the electrolyte jet. The electrolyte is impacted on the surface of the workpiece and then is scattered to form an electrolyte flowing film, compared with the size of a jet liquid column, the thickness of the electrolyte flowing film is extremely thin, most of current is bound under the electrolyte column, and the current density at the electrolyte flowing film is rapidly reduced. Therefore, the electrolytic machining is characterized by high localization, and high current density machining is only carried out in a certain area under the electrolyte jet flow liquid column. Therefore, after the nozzle is clamped on the main shaft of the numerical control machine tool, the forming processing of various complex structures can be completed on the surface of a workpiece through numerical control programming and parameter control, and the nozzle is widely concerned by researchers at home and abroad. However, when a workpiece having a large height difference with an uneven surface is electrolytically machined, there is a genetic error, and the height difference of the workpiece surface cannot be eliminated by simply performing electrolytic machining.
In view of the advantages of electric discharge machining and electrolytic machining, respectively, there have also been many studies on electric discharge-electrolytic combination or combined machining. In the electric spark-electrolysis combined machining, firstly, an electric spark technology is adopted for machining, after the electric spark machining is finished, other tools or equipment are required to be adopted for electrolytic machining, a recast layer is removed by utilizing an electrochemical dissolution reaction, and the surface quality is improved. However, there is a certain time difference between the electric discharge machining and the electrolytic machining, and the electric discharge machining and the electrolytic machining are not continuous machining. During the time difference, the electro-discharge machined surface may also form an oxide layer again, which may prevent the subsequent electrolytic machining from being performed efficiently. In addition, after the electric discharge machining, whether electrolytic machining is performed using another tool or equipment, operations such as tool setting must be performed first, which consumes a certain amount of time and reduces machining efficiency. For electric spark-electrolysis combined machining, the current research is mainly to remove materials by electric sparks, and is assisted to remove recast layers of electric spark machining by electrolysis, and most of the adopted solution is ultra-low concentration salt solution, so that high-efficiency electrolysis cannot be realized; some researchers try to realize composite electrolytic machining by simultaneously spraying low-concentration solution required by electric spark discharge and high-concentration solution required by electrolysis during machining, but the two solutions with different concentrations cannot be reused after machining by the method, and the method is not beneficial to long-term large-scale industrial production.
Disclosure of Invention
The invention provides an electrolytic electric spark composite leveling tool and method for manufacturing a rough metal surface in an additive manufacturing mode.
The utility model provides a compound flattening instrument of electrolysis electric spark of additive manufacturing metal rough surface which characterized in that: the device consists of a front end electrolysis electrode, an electric spark electrode and a rear end electrolysis electrode which are sequentially arranged from front to back; hollow flow channels are arranged in the front end electrolysis electrode and the rear end electrolysis electrode.
The method for manufacturing the electrolytic electric spark composite leveling tool for the metal rough surface in an additive mode is characterized by comprising the following steps of: the combined tool is utilized to realize the sequential continuous processing of electrolysis-electric spark-electrolysis, and the specific process is as follows: firstly, spraying electrolyte to the surface of an additive manufacturing metal workpiece by using a front-end electrolytic electrode, carrying out electrolytic machining on the surface of the additive manufacturing metal workpiece, removing extremely high points on the surface of the workpiece, preliminarily leveling the surface of the workpiece, reducing the height difference of the surface of the additive manufacturing metal workpiece, providing conditions for subsequent electric spark machining and preventing short circuit of the electric spark machining; then, carrying out electric spark machining on the surface of the additive manufacturing metal workpiece subjected to spray electrolytic machining by using an electric spark electrode to quickly remove higher points remained on the surface of the additive manufacturing metal workpiece, and eliminating the genetic error problem which cannot be solved by electrolytic machining; and finally, spraying electrolyte to the surface of the flat but rough additive manufacturing metal workpiece after the electric spark machining by using the rear end electrolytic electrode, and carrying out electrolytic machining to further smooth the flat but rough surface after the electric spark machining.
The front-end electrolytic electrode is used for spraying electrolyte to the surface of the metal workpiece to be subjected to additive manufacturing, electrolytic machining is carried out on the metal workpiece to remove extremely high points on the surface of the workpiece, the surface of the workpiece is preliminarily leveled, the height difference of the surface of the metal workpiece to be subjected to additive manufacturing is reduced, conditions are provided for subsequent electric spark machining, and short circuit of the electric spark machining is prevented; in the electrolytic jet machining, the machining gap at the higher point of the workpiece is small, the electrolyte fluid column is short, and the electrolytic machining resistance is small, so that the machining current density is high, and the higher point of the workpiece can be quickly removed by electrolysis. On the contrary, the lower part of the workpiece has large processing clearance, long electrolyte fluid column and large electrolytic processing resistance, so the processing current density is low, and when the current density is low to a certain value, an oxide layer is generated at the lower part due to the electrolytic action, so the lower point of the workpiece can not be removed by electrolysis basically. Finally, the electrolytic machining makes the unevenness height difference of the workpiece surface smaller. However, when the level difference of the surface of the workpiece is lower than a certain value, the low point is electrolyzed, so that the level difference of the surface of the workpiece is always present, and finally the surface of the workpiece is difficult to be completely leveled, which is called as a genetic error of the electrolytic machining.
Therefore, after that, the electric spark electrode is used for carrying out electric spark machining on the surface of the additive manufacturing metal workpiece subjected to the jet electrolysis machining of the front end electrolysis electrode, so that the residual higher points on the surface of the additive manufacturing metal workpiece are quickly removed, and the genetic error problem which cannot be solved by the electrolysis machining is eliminated; because the high point of the surface bulge of the workpiece is punctured preferentially under higher voltage during electric spark machining, the high point is removed instantly, and the low point cannot be punctured by electric spark because the low point does not reach the puncture voltage. But the spark explosively removes material by heat, so the machined surface is generally flat but rough.
And finally, spraying electrolyte to the surface of the flat but rough additive manufacturing metal workpiece after the electric spark machining by using the rear end electrolytic electrode, and carrying out electrolytic machining to further smooth the flat but rough surface after the electric spark machining.
The electrolytic electric spark composite leveling tool for the additive manufacturing of the rough metal surface is characterized in that: the relative heights of the front-end electrolytic electrode, the electric spark electrode and the rear-end electrolytic electrode are adjustable. The processing energy density of electrolytic processing and electric spark processing can be controlled by adjusting the relative heights of different electrodes so as to flexibly adapt to the leveling requirements of additive manufacturing metal workpieces with different surface appearances;
the electrolytic electric spark composite leveling combined tool for manufacturing the rough metal surface by the additive manufacturing is characterized in that: the distance between the end face of the front-end electrolysis electrode and the surface of the workpiece is larger than that between the end face of the rear-end electrolysis electrode and the surface of the workpiece; the electric spark electrode is of an inclined end face structure, the distance between one end of the electric spark electrode, close to the front end electrolysis electrode, and the surface of the workpiece is larger than the distance between the other end of the electric spark electrode and the surface of the workpiece, and the end serves as a front cutter face. The electric spark electrode with the inclined end face is designed into the inclined end face, so that the machining depth can be fully achieved in the feeding process, and meanwhile, the safety distance is ensured to prevent short circuit.
The electrolytic electric spark composite leveling method for the rough surface of the metal manufactured by the additive is characterized by comprising the following steps of: the front-end electrolysis electrode, the electric spark electrode and the rear-end electrolysis electrode respectively control the voltage applied to the electrodes, so that the discharge intensity or the electrolysis intensity of each section can be flexibly controlled; and respectively controlling the electrolyte spraying speeds of the hollow front-end electrolytic electrode and the hollow rear-end electrolytic electrode to change the fluid speed of the electrolyte and the liquid film thickness of the fluid, thereby changing the electric spark discharge intensity and the electric field distribution.
Drawings
FIG. 1 is a schematic diagram of electrolytic-spark-electrolytic continuous leveling;
FIG. 2 is a schematic diagram comparing electrolytic machining and electrolytic-spark-electrolytic continuous machining;
FIG. 3 is a process schematic diagram of a process for electro-spark electrolytic leveling of an additive manufactured metal;
wherein the designation of the reference numbers: 1. the rear end electrolytic electrode, 2, the electric spark electrode, 3, the electrolyte jet flow direction, 4, the cutter feeding direction, 5, the front end electrolytic electrode, 6, the workpiece and 7, the common electrolytic electrode.
Detailed Description
In the schematic diagram of electrolysis-electric spark-electrolysis continuous leveling shown in fig. 1, an electrolysis-electric spark-electrolysis combined tool is used, which is composed of a front end electrolysis electrode 5, an electric spark electrode 2 and a rear end electrolysis electrode 1; hollow flow channels are arranged in the front end electrolysis electrode and the rear end electrolysis electrode; the electrolysis-electric spark-electrolytic machining is carried out according to the following sequence: as shown in the area A, firstly, the front-end electrolytic electrode 5 is utilized to spray electrolyte to the surface of an additive manufacturing metal workpiece 6, electrolytic machining is carried out on the surface of the workpiece, extremely high points on the surface of the workpiece are removed, the surface of the workpiece is preliminarily leveled, the height difference is reduced, conditions are provided for subsequent electric spark machining, and short circuit is prevented; as shown in the area B, after the electrolytic machining, the surface of the additive manufacturing metal workpiece 6 is subjected to the electric spark machining by using the electric spark electrode 2, so that higher points on the surface of the additive manufacturing metal workpiece 6 are quickly removed, and genetic errors which cannot be solved by the electrolytic machining are eliminated; as shown in region C, immediately after the electric discharge machining, the electrolyte is sprayed to the surface after the electric discharge machining by the rear-end electrolytic electrode 1, and the electrolytic machining is performed to further smooth the flat but rough surface after the electric discharge machining. Wherein, the distance h between the front end electrolysis electrode 5, the electric spark electrode 2 and the rear end electrolysis electrode 1 and the surface of the workpiece 61、h2、h3Can be adjusted according to the actual processing requirement.
FIG. 2 is a schematic diagram showing a comparison between electrolytic machining and electrolytic-spark-electrolytic continuous machining. As can be seen from fig. 2 (a), when only the electrolytic electrode is used to perform electrolytic machining on the surface of the additive manufacturing metal, due to the large height difference of the surface of the workpiece and the characteristics of the electrolytic machining itself, there is a genetic error, and the height difference of the surface of the workpiece cannot be completely eliminated, so that the subsequent electric discharge machining is required to remove the high point, as shown in fig. 2 (b), to further achieve leveling of the surface of the workpiece.
Fig. 3 is a schematic view showing the process of the electric spark electrolytic leveling process for the additive manufacturing metal, when the machining tool moves horizontally, the front end electrolytic electrode 5 is firstly utilized to spray the electrolyte onto the surface of the additive manufacturing metal workpiece 6, and the electrolytic machining is carried out on the surface of the additive manufacturing metal workpiece to remove the extremely high points on the surface of the workpiece, primarily level the surface of the workpiece, reduce the height difference and provide conditions for the subsequent electric spark machining; the electric spark electrode 2 which follows the surface of the metal workpiece 6 is used for carrying out electric spark machining on the surface of the metal workpiece 6, so that higher points on the surface of the metal workpiece 6 are quickly removed, and genetic errors are eliminated; the rear-end electrolytic electrode 1 immediately following the electrolytic machining is subjected to electrolytic machining to further smooth the flat but rough surface after the electric discharge machining.
Claims (4)
1. The utility model provides a compound flattening instrument of electrolysis electric spark of additive manufacturing metal rough surface which characterized in that:
the electrolytic electric spark composite leveling tool for the rough surface of the metal manufactured by the additive consists of a front end electrolytic electrode (5), an electric spark electrode (2) and a rear end electrolytic electrode (1) in sequence from front to back; hollow flow channels are arranged in the front end electrolysis electrode (5) and the rear end electrolysis electrode (1);
the distance between the end surface of the front-end electrolytic electrode (5) and the surface of the workpiece is larger than the distance between the end surface of the rear-end electrolytic electrode (1) and the surface of the workpiece; the electric spark electrode (2) is of an inclined end face structure, the distance between one end, close to the front end electrolytic electrode, of the inclined end face structure of the electric spark electrode (2) and the surface of the workpiece is larger than the distance between the other end of the inclined end face structure of the electric spark electrode and the surface of the workpiece, and the end, close to the front end electrolytic electrode, of the inclined end face structure of the electric spark electrode (2) is used as a rake face.
2. The additive manufacturing metallic matte surface electrolytic spark composite flattening tool of claim 1, wherein: the relative heights of the front-end electrolysis electrode (5), the electric spark electrode (2) and the rear-end electrolysis electrode (1) are adjustable.
3. The method for the additive manufacturing of the electrolytic spark-flattening composite tool for rough metal surfaces according to claim 1, characterized in that it comprises the following steps:
the electrolytic electric spark composite leveling tool for manufacturing the rough metal surface by the additive realizes sequential continuous machining of electrolysis-electric spark-electrolysis, and comprises the following specific processes:
firstly, spraying electrolyte to the surface of an additive manufacturing metal workpiece (6) by using a front-end electrolysis electrode (5), carrying out electrolytic machining on the surface of the additive manufacturing metal workpiece, removing extremely high points on the surface of the workpiece, primarily leveling the surface of the workpiece, reducing the height difference of the surface of the additive manufacturing metal workpiece, providing conditions for subsequent electric spark machining and preventing short circuit of the electric spark machining;
then, carrying out electric spark machining on the surface of the additive manufacturing metal workpiece (6) subjected to spray electrolytic machining on the front end electrolytic electrode (5) by using the electric spark electrode (2), quickly removing higher points remained on the surface of the additive manufacturing metal workpiece (6), and eliminating the genetic error problem which cannot be solved by electrolytic machining;
and finally, spraying electrolyte to the surface of the flat but rough additive manufacturing metal workpiece (6) after the electric spark machining by using the rear end electrolysis electrode (1), and performing electrolytic machining to further smooth the flat but rough surface after the electric spark machining.
4. A method for electrolytic electric spark composite leveling tool with metal rough surface using additive manufacturing according to claim 3, characterized in that:
the front-end electrolysis electrode (5), the electric spark electrode (2) and the rear-end electrolysis electrode (1) respectively control the voltage applied to the electrodes, so that the discharge intensity or the electrolysis intensity of each section can be flexibly controlled;
the electrolyte spraying speeds of the front end electrolysis electrode (5) and the rear end electrolysis electrode (1) are respectively controlled to change the fluid speed of the electrolyte and the liquid film thickness of the fluid, so that the electric spark discharge intensity and the electric field distribution are changed.
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| EP1757395A1 (en) * | 2005-08-26 | 2007-02-28 | Asulab S.A. | Machining head for spark erosion machining assisted with chemical etching. |
| CN103480926B (en) * | 2013-09-10 | 2016-06-01 | 南京航空航天大学 | The synchronous combined machining method in the different district of micro-hole electric spark-electrolysis and special tool thereof |
| CN104439571A (en) * | 2014-11-30 | 2015-03-25 | 重庆新红旗缸盖制造有限公司 | EDM shaping machine structure |
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