CN113478031B - Flexible electrode dynamic deformation electrolytic machining method and application - Google Patents

Flexible electrode dynamic deformation electrolytic machining method and application Download PDF

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CN113478031B
CN113478031B CN202110860375.5A CN202110860375A CN113478031B CN 113478031 B CN113478031 B CN 113478031B CN 202110860375 A CN202110860375 A CN 202110860375A CN 113478031 B CN113478031 B CN 113478031B
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machining
workpiece
profile
electrode
tool
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CN113478031A (en
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朱荻
徐正扬
刘琳
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Nanjing University of Aeronautics and Astronautics
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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
    • B23H3/00—Electrochemical machining, i.e. removing metal by passing current between an electrode and a workpiece in the presence of an electrolyte
    • 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
    • B23H3/00—Electrochemical machining, i.e. removing metal by passing current between an electrode and a workpiece in the presence of an electrolyte
    • B23H3/04—Electrodes specially adapted therefor or their manufacture
    • 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
    • B23H3/00—Electrochemical machining, i.e. removing metal by passing current between an electrode and a workpiece in the presence of an electrolyte
    • B23H3/04—Electrodes specially adapted therefor or their manufacture
    • B23H3/06—Electrode material
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P10/00—Technologies related to metal processing
    • Y02P10/25—Process efficiency

Abstract

The invention relates to a dynamic deformation electrolytic machining method for a flexible electrode and application thereof, belonging to the technical field of electrolytic machining. The method is characterized in that: tubular or bar-shaped metal with certain rigidity but capable of bending and deforming when corresponding load is applied is used as a tool electrode for electrochemical machining, and when a complex profile surface such as a closed blisk is machined, the side wall of the tool electrode is used as a machining surface to perform sweep electrochemical machining along the surface of the complex profile surface of a workpiece. In the machining process, according to the curvature change characteristics of the profile of the workpiece, the tool electrode is dynamically deformed while being fed by applying different loads, and the deformed shape of the tool electrode is similar to a mathematical model of the profile line of the workpiece, so that the machined profile of the workpiece is close to an ideal profile. The invention processes the complex profile of the closed blisk by the electrode with simple shape, improves the electrolytic processing efficiency and ensures the processing precision.

Description

Flexible electrode dynamic deformation electrolytic machining method and application
Technical Field
The invention relates to a dynamic deformation electrolytic machining method for a flexible electrode and application thereof, belonging to the technical field of electrolytic machining.
Background
The blisk part integrates the blade and the hub and replaces a connecting structure of a blade tenon tooth, a hub mortise and a locking plate, so that the number of parts is reduced, the weight of an aeroengine is reduced, and the working efficiency of the engine is improved. As a core part in an aircraft engine, the performance of the whole aircraft engine is directly influenced by the quality of the machining and manufacturing quality of a blisk. The blisk can be divided into an open blisk and a closed blisk according to the existence of a blade crown structure at the top of the blade, and the closed blisk is additionally provided with a full-circle blade crown structure at the top of the blade, so that the flutter of the blade can be effectively inhibited; the flow loss of the working medium is reduced; the integral strength and rigidity of the blade disc are improved, so that the application of the closed type integral blade disc in the aerospace field is continuously increased.
But the structure is complex, the blade profile is twisted, and the material which is difficult to process such as high-temperature alloy is usually adopted, so that great difficulty is brought to processing and manufacturing. At present, the manufacturing process of the closed blisk mainly comprises the steps of traditional machining, precision casting, electric spark machining, electrolytic machining and the like.
In the patent "high-precision closed vane disk forming method" (application No. 201210588218.4 applicant, national institute of general accomplishment of the liberty military, inventor wu high-strength shixiaohuang zhuang yu chi wei), a closed vane disk is split into a cover plate, a vane and a chassis, machining is completed through machining processes such as water jet cutting, turning, grinding and the like, the closed vane disk is welded into a whole by vacuum brazing, stress relief processing is performed after welding, and then machining is performed to obtain a finished product.
In the patent 'a method for controlling the size of a closed impeller investment precision casting runner' (application number 201911206733.X applicant Xian aerospace engine Co., Ltd., inventor Yang Huan Wang Lin high Huan Jing Yan Wu Xiao Cheng Rong), the provided runner size control method solves the problem of poor precision of the closed impeller investment precision casting runner size, improves the product hydraulics performance index, saves the product trial production period and reduces the manufacturing cost.
In a small-gap closed aluminum alloy impeller laser selective melting forming method (application number 201910550775.9 applicant, west safety space engine limited company, inventor li baoling pople celebration wang lin thunder key), process precompensation and addition of a columnar support convenient to remove are adopted, size precision, shape precision and surface roughness of an inner flow passage are guaranteed, and integral additive manufacturing of the small-gap closed aluminum alloy impeller becomes possible.
In a patent 'closed impeller and a forming method thereof' (the university of Suzhou of the applicant of application No. 201811546242.5, inventor Shituchen Leishi Honglunfu Gaoyan), a laser cladding forming technology of optical internal powder feeding is adopted, and the problem of position interference can be effectively avoided through obliquely oriented blade stacking and bridging forming, so that the blade stacking part and the bridging part have good appearance.
In a patent 'a closed impeller electric spark machining device and a machining method' (application number 201611208198.8 applicant Beijing commercial power machining research institute, inventor Li Yanv gold Juanyang Guoshi beautiful in sail), a plurality of pre-machining electrodes are proposed to be arranged in a circle, and the number of the pre-machining electrodes is the same as that of flow channels of a closed impeller to be machined; and each preprocessing electrode corresponds to one runner inlet of the closed impeller to be processed during processing, so that the problem of low processing efficiency caused by independent processing of each runner of the closed impeller in the prior art is solved.
Electrolytic machining is a process based on the principle of anodic dissolution and by means of a shaped cathode, for shaping a workpiece to a certain shape and size. Because the electrochemical machining process has the advantages of no influence of mechanical properties of materials, no generation of macroscopic stress, no tool loss, high material removal rate and the like, the electrochemical machining process is widely applied to the fields of aerospace, automobiles, weapons and the like, and particularly in the machining and manufacturing of blisk parts of aircraft engines, the electrochemical machining process becomes one of the main machining processes for machining and manufacturing the blisk parts.
At present, the electrolytic machining process of the blisk mainly comprises two steps, namely rough machining of a blade cascade channel and fine machining of a blade profile. Numerous researchers and researchers have conducted extensive research into the electrochemical machining of blisk cascade channels and blisk blade profiles. The electrolytic machining method of the blisk cascade channel mainly comprises nesting electrolytic machining, radial feeding electrolytic machining and numerical control electrolytic machining. The electrolytic machining method for the blade profile of the blisk mainly processes and shapes the blade profile through the opposite feeding of two shaped cathodes.
In a patent "an electrode for electrolytic grooving of a blisk and a method for electrolytic grooving of a blisk" (application No. 201410513097.6 applicant, shenyang daoming aeroengine (group) llc, inventor wangdi new ju hainan in an icy silk), the uniformity of a margin after grooving processing is improved by a trepanning electrolytic processing method.
In a patent of 'a ring electrode processed by blisk electrolytic grooving and a process method' (Shenyang dawn aircraft engine (group) finite liability company, inventor Zhuhainan poplar stone-ice plum Wei, of the applicant of application No. 201210367002.5), efficient processing of blisk wide-chord and large-twist-angle blade-shaped channel grooving is realized in a manner of trepanning electrolytic processing.
In the patent "cathode system and processing method for electrolytic processing of insulation shielding trepanning" (application number 201710202429.2 applicant Nanjing aerospace university, inventor of Zhu Dan Hexing Yan Zhu silvergrass), a cathode system and processing method for electrolytic processing of insulation shielding trepanning are provided, which can effectively reduce the secondary corrosion of stray current to the surface of a workpiece and improve the surface quality of a processed molded surface.
In the article, "blisk radial electrochemical machining cathode design and experiment based on blade cascade channel machinability analysis" (the authors in Sun and Rong, Xuzhengyang, Zhu di, China mechanical engineering, 09 years 2013), a radial electrochemical machining method is proposed, and simultaneously the molding surfaces of a blade basin, a blade back and a hub are formed, so that high-precision and high-efficiency machining is realized.
In the patent of 'blisk electrolytic machining tool and method capable of realizing linear and rotary combined feeding' (Nanjing aerospace university, inventor Xuzheng Yangxiang Polychen Liujia Zhu dong miscanthus) of the patent application number 201410013249.6, composite rotary motion of a formed cathode in the radial feeding machining process is provided, the process applicability can be improved, a cascade channel with a complex twisted profile is machined, and the machining precision and the level of the cascade channel are improved.
In a patent 'space rotation feeding composite workpiece inclined swinging blisk electrolytic machining method' (Nanjing aerospace university of applicant 201410457130.8, inventor Liujiafang Zhongdong Xuzhengyang red silvergrass of Judong Guzhou), the electrolytic machining of a blisk blade grid channel is completed in a mode that a tool space rotation feeding composite workpiece is inclined and swung, the machining allowance difference of the blade grid channel is obviously reduced, and the machining precision of the blisk blade grid channel is improved.
In a patent 'a non-uniform double-rotation transformation processing blade cathode blisk electrolytic processing method' (Nanjing aerospace university, inventor Xun Yang Wang Jingzhu silvergrass, Nanjing of the applicant of 201910756930.2), a processing blade of a cathode is designed to be a widening processing blade, and is driven to rotate radially and feed in a unidirectional variable speed mode according to a simulation track; the blank is driven to rotate in a variable speed mode in cooperation with the cathode direction change according to simulation optimized parameters, a cascade channel is formed on the blank, and the distribution uniformity of machining allowance is improved.
In the patent "cathode of variable tool for inner cavity of electrochemical machining of blisk with large twisted blade" (application number 201910326896.5 applicant Anhui university of Enhan university of inventor, inventor Sun industry Hao Wang), the cathode of variable tool for electrochemical machining of inner cavity of blisk with large twisted blade is proposed for machining of blisk with large twisted variable section.
In the patent of 'a blisk electrolytic machining method' (application number 201811128151.X applicant, China aviation manufacturing technology research institute, inventor, Huang Ming Tao Zhang Ming Qigong Fu Junying), after a tool cathode is radially fed to machine a blade grid channel, the blisk is driven to rotate clockwise and anticlockwise, and electrolytic finish machining is carried out close to the tool cathode.
In the article, "large-diameter integral impeller step-by-step electrolytic machining process and test" (the author wang fu yuan xu home culture Zhao Jian, the university, 12 th 2010), step-by-step numerical control electrolytic machining is proposed, and blade machining is divided into 3 procedures of machining a blade basin, a blade back and a blade root to carry out electrolytic machining.
In the patent ' multi-electrode spiral feeding integral impeller inter-blade flow channel electrolytic machining method ' (Nanjing aerospace university of applicant ' 200910025834.7, inventor Zhu Yao Xuqing Xuzhengyang), a blade grid channel is machined by using a tubular electrode with a simple shape through multi-dimensional interpolation motion between a tool cathode and a workpiece anode.
In the patent of 'blisk profile electrolytic machining device and method based on three-dimensional composite flow field' (Nanjing aerospace university, inventor Lijiawan Longkangxing Zhengyang Zhudong, Nanjing, application number 201310453440.8 applicant), the proposed three-dimensional composite flow field effectively improves the pressure of fluid in a flow channel mutation area, improves the accessibility of the flow field, and simultaneously ensures the stability of an electrolyte flow field, prevents the electrolyte from leaking, isolates external interference, and realizes the stable machining of the blisk profile.
The blisk is divided into an open blisk and a closed blisk, wherein the blisks can be subdivided into a plurality of types such as axial flow type blisks, guide type blisks and centrifugal type blisks, and higher requirements are provided for an electrolytic machining method and equipment. For the blisk with complex twisted blade profiles, the design of the corresponding electrochemical machining cathode is also complex, if the design of the cathode can be simplified, the complex profiles are machined through the cathode with a simple shape, the machining precision can be guaranteed, the electrochemical machining efficiency of the blisk is undoubtedly improved, the preparation period is shortened, and the machining cost is reduced. Therefore, the invention provides a dynamic deformation electrolytic machining method for a flexible electrode.
Disclosure of Invention
The purpose of the invention is as follows:
the invention aims to simplify the design of a cathode, process a complex profile such as a closed blisk by a simple-shaped electrode, improve the electrolytic processing efficiency, ensure the processing precision and provide a dynamic deformation electrolytic processing method of a flexible electrode and application thereof.
The technical scheme is as follows:
the dynamic deformation electrolytic machining method for the flexible electrode is characterized by comprising the following steps of:
the tubular or rod-shaped metal which has good corrosion resistance and certain rigidity, can be bent and deformed when corresponding load is applied, and can be recovered when the load is removed is adopted as the tool electrode for electrolytic machining. When a complex profile surface such as a closed blisk is machined, the side wall of the tool electrode is used as a machining surface to perform sweeping type electrolytic machining along the surface of the complex profile surface of a workpiece. In the machining process, according to the curvature change characteristics of the profile of the workpiece, the tool electrode is dynamically deformed while being fed by applying different loads, and the deformed shape of the tool electrode is similar to a mathematical model of the profile line of the workpiece, so that the machined profile of the workpiece is close to an ideal profile.
The dynamic deformation of the flexible electrode is characterized by comprising the following processes:
step 1, establishing a relation between the deformation curvature of the flexible electrode and the curvature of the profile of the workpiece according to standard profile sampling data of the workpiece to be machined, wherein the mathematical model establishment process is as follows:
step 1-1, sampling the molded surface of a processed workpiece, researching the electrolytic machining forming rule of the molded surface by applying a cos theta method, and simplifying and approximating a complex electric field in an actual machining gap, wherein the method is mainly based on the following assumptions:
(1) the potential gradient along the direction of the current line is unchanged, namely the electric field intensity on the same current line is the same;
(2) from the anode equipotential surface to the cathode equipotential surface, the potential is gradually reduced, and the equipotential surface is orthogonal to the current line;
(3) the conductivity kappa of the electrolyte in the processing gap is uniformly distributed;
1-2, after simplifying approximate treatment, obtaining an equation set related to a forming rule according to the basic principles of electrolytic machining of ohm law and Faraday law:
UR＝U-δE
Figure GDA0003537918660000051
va＝ηωi
in the formula: u shapeRIs the voltage drop in the interstitial electrolyte; u is the voltage between the cathode and the anode; delta E is the sum of the potential values of the cathode and the anode electrodes; i is the current density; kappa is the electrolyte conductivity; delta is the machining gap; v. ofaThe workpiece electrolysis speed; η is the current efficiency; omega is volume electrochemical equivalent;
step 1-3, when the electrolytic machining reaches an equilibrium state, the electric field parameters do not change along with time, but only are functions of spatial positions, namely, the gap electric field is a stable and constant electric field; establishing related workpiece electrolysis speed v according to ohm law and Faraday lawaThe basic equation of (1): v. ofaAnd (3) deriving a calculation formula of the machining gap delta by a simultaneous equation set as v cos theta:
Figure GDA0003537918660000052
in the formula: v is the cathode feed speed; theta is an included angle between the normal direction of the profile of the workpiece and the feeding direction of the cathode; deltabMachining the gap for balance;
step 1-4, the tool cathode is a long and thin tubular or rod electrode to carry out sweep type electrolytic machining, so that the tool cathode can be simplified into a two-dimensional curve, and the sweep process of the curve is the machined workpiece profile. Therefore, in the dynamic deformation process of the flexible electrode, the coordinate relationship between each point of the flexible electrode (cathode) and the corresponding sampling point of the profile of the workpiece is as follows:
x＝xa-Δcosα
y＝ya-Δcosβ
in the formula: x and y are coordinate values of a certain point on the cathode profile of the tool, xaAnd yaThe coordinate values of the corresponding workpiece profile sampling points are shown, and alpha and beta are respectively included angles between the workpiece profile sampling points and coordinate axes X and Y;
step 1-5, performing polynomial fitting on the obtained coordinate values of the tool cathode profile to obtain a functional relation between y and x:
Figure GDA0003537918660000061
in the formula: k is the order of the polynomial, t0，...，tKIs a polynomial coefficient, denoted as T;
step 1-6, obtaining the curvature of each point of the flexible electrode (cathode) in the dynamic deformation process of the flexible electrode according to the curvature formula and the function relation of y and x obtained in the step 1-5:
Figure GDA0003537918660000062
in the formula: y (x) 'is the first derivative of y (x, T), and y (x)' is the second derivative of y (x, T);
step 2, determining the size of the load required in the dynamic deformation sweep type electrochemical machining process of the flexible electrode by combining the relation between the deformation curvature of the flexible electrode and the load; the relation between the deformation curvature of the flexible electrode and the borne load is established through the following mathematical model:
step 2-1, after the tool cathode is installed, simplifying the tool cathode into a simply supported beam model with one end being restrained by a fixed end, one end being hinged and the length being l, establishing a coordinate system with the length direction of the tool cathode as an X axis and the radial direction of the section of the tool electrode as a Y axis, wherein the boundary condition of the simply supported beam model is that the deflection of the constraint condition at the hinged position is 0;
step 2-2, under the condition that shear stress is neglected in pure bending deformation and transverse force bending deformation, bending moment and transverse force bending deformationThe relationship between curvatures is:
Figure GDA0003537918660000063
wherein ρ is the curvature, M is the applied load, E is the elastic modulus of the material, I is the moment of inertia, and EI is its bending stiffness; calculating an approximate differential equation for the resulting flexible line:
Figure GDA0003537918660000064
wherein w is deflection;
step 2-3, the angular displacement of the cross section to the original position is called as the corner of the cross section, and according to a corner equation:
Figure GDA0003537918660000065
calculating to obtain: EIw ═ m (x) dx + C, where γ is the angle of rotation, w' is the first derivative of deflection, and C is the integral constant;
step 2-4, integrating the above equation to obtain a deflection equation:
Figure GDA0003537918660000071
further simplifying as follows: EIw ═ jjj (m (x) dx) dx + Cx + D, where w is the deflection and C, D are integral constants;
and 2-5, substituting the boundary conditions into the formula to obtain a deflection equation:
Figure GDA0003537918660000072
wherein M is the applied load, l is the length of the tool electrode, and x is the abscissa of any point of the tool electrode;
and 2-6, obtaining the curvature of the point at any point according to a curvature formula:
Figure GDA0003537918660000073
wherein
Figure GDA0003537918660000074
w' is the first derivative of the deflection,
Figure GDA0003537918660000075
w' is a deflection of twoA first derivative;
step 3, obtaining the change of the flexible electrode curvature corresponding to the workpiece profile in the machining process according to a flexible electrode deformation curvature and workpiece profile model established according to the standard profile sampling data of the machined workpiece, and obtaining the change of the load borne by the flexible electrode in the machining process according to the relation between the flexible electrode deformation curvature and the load borne by the flexible electrode;
and calculating by combining the two models to obtain the applied load, so that the flexible electrode realizes the dynamic deformation of the standard molded surface of the fitting machining workpiece in the sweeping type machining process.
The flexible electrode is in a simple tubular or rod shape, and the dynamic deformation of the flexible electrode, which is attached to the workpiece profile in the sweep type electrolytic machining, is realized by establishing the relation between the deformation curvature of the flexible electrode and the profile curvature of the workpiece and the relation between the deformation curvature of the flexible electrode and the load, so that the machined workpiece profile is closer to an ideal profile. The cathode design is simplified, and the processing efficiency of complex-profile workpiece processing is improved.
The dynamic deformation electrolytic machining method of the flexible electrode is characterized in that the flow field is as follows: because of the deformation and displacement of the tool electrode in the machining process, in order to avoid the unfavorable phenomena of a liquid shortage area and the like in the machining process, the flowing form of the electrolyte is designed to be a lateral flow type, the flow field is an open type or semi-closed type flow field, and the electrolyte flows along the axial direction of the tool cathode through an additional electrolyte supply device.
The flexible electrode dynamic deformation electrolytic machining method is applied to the machining of parts with variable cross-section molded surfaces, and is characterized in that: installing the tool electrode and the processing workpiece, reasonably adjusting the position relation of the tool electrode and the processing workpiece, applying different loads according to the curvature change characteristics of the processed variable cross-section profile part, and enabling the tool electrode to realize dynamic deformation of the fit standard profile in the sweeping type processing process, so that the processed workpiece profile is close to the ideal profile, and the processing of the part with the variable cross-section profile is completed.
The flexible electrode dynamic deformation electrolytic machining method is applied to the machining of parts with variable cross-section molded surfaces, and is characterized in that: the method is particularly applied to machining of the closed blisk, straight holes with equal blade number are pre-opened on the blank of the closed blisk according to the blade distribution positions, and tool electrodes are convenient to mount; in the pre-through straight hole, a complex twisted channel of the closed blisk is processed in a sweep type electrolytic processing mode of controllable dynamic deformation of the flexible electrode.
The flexible electrode dynamic deformation electrolytic machining method is applied to the machining of parts with variable cross-section molded surfaces, and is characterized in that: the method is particularly applied to electrolytic machining of closed blisk cascade channels, and is characterized in that: the tool electrode (2) is connected to the processing shaft through the cathode clamping shaft (1), and the tool electrode (2) is driven to move through the spatial movement of the processing shaft and applies corresponding load; the closed blisk machining workpiece (3) is arranged on the workpiece rotating platform (4), and the closed blisk machining workpiece (3) is driven to rotate through the workpiece rotating platform (4); through the compound motion of the tool electrode (2) and the closed blisk machining workpiece (3), the electrochemical machining gap is controlled, and the sweeping type electrochemical machining which is performed along the surface of the complex profile of the workpiece by taking the side wall of the tool electrode (2) as a machining surface is realized.
Has the advantages that:
compared with the prior art, the invention has the following remarkable advantages.
(1) A dynamic deformation electrolytic machining method for flexible electrode is provided. The method is characterized in that a metal material which has good corrosion resistance and certain rigidity and can generate bending deformation when corresponding load is applied is selected to be made into an elongated tubular or rod-shaped flexible tool electrode, the side wall of the tool electrode is used as a processing surface to carry out sweep type electrolytic processing along the surface of the complex profile of a workpiece when processing is carried out, different loads are applied according to the curvature change characteristics of the profile of the workpiece, so that the tool electrode generates dynamic deformation when feeding, and the electrolytic processing of complex profile parts with variable cross sections such as a closed integral blade disc is realized.
(2) An electrolytic machining method of a closed blisk is provided. The flexible electrode dynamic deformation electrolytic machining is applied to the machining of the closed blisk. Straight holes with equal number of blades are pre-opened on the blank of the closed blisk according to the blade distribution positions, so that the flexible electrode can conveniently penetrate through the straight holes to be installed; in the pre-through straight hole, a complex twisted channel of the closed blisk is processed in a sweep type electrolytic processing mode of controllable dynamic deformation of the flexible electrode.
(3) The flexibility of the tool electrode is good, and the dynamic deformation of the tool electrode can ensure the processing precision. The cathode designed by the invention is made of a metal material with good corrosion resistance, certain rigidity and ductility, can generate bending deformation when a corresponding load is applied, and can rebound and recover from deformation when the load is removed. In the machining process, different loads are applied according to the curvature change characteristics of different positions of the workpiece profile, so that corresponding dynamic deformation is generated at different positions of the tool electrode in the feeding process, the machined workpiece profile is closer to an ideal profile, and the machining precision is ensured.
(4) The design of the cathode is simplified, and the cathode is easy to process and obtain. The cathode designed by the invention is in a slender tubular or rod shape, and compared with the sleeve material electrolytic machining and the radial feeding electrolytic machining, the cathode is simple in design and easy to manufacture, and the cathode is convenient to replace after being damaged, so that the cathode manufacturing period is shortened, the time cost is reduced, and the processing efficiency is improved.
(5) The method has wide application range, and can be used for processing the uniform-section blade with a simple blade profile and the variable-section blade with a complex blade profile. The cathode of the invention is a flexible deformable slender tubular or rod-shaped tool electrode, and different loads can be applied according to different profiles of machined workpieces and the curvature change characteristics of the profiles, so that the tool electrode generates different deformations, and electrolytic machining is carried out. In addition, the diameter of the flexible electrode can be reduced as much as possible, so that the processing requirement of a narrow channel is ensured.
Drawings
FIG. 1 is a schematic diagram showing the electrochemical machining molding rule by cos θ method;
FIG. 2 is a schematic diagram of tool cathode coordinate system establishment;
FIG. 3 is a schematic view of the electrolytic machining principle in the initial position;
FIG. 4 is a schematic view of the principle of electrolytic machining during machining;
FIG. 5 is a schematic diagram of the deformation principle of the flexible electrode;
number designation in the figures: 1. a cathode clamping shaft 2, a tool electrode 3, a closed blisk processing workpiece 4 and a workpiece rotating platform.
Detailed Description
The following describes the specific implementation of the present invention in detail by taking the electrochemical machining of closed blisk cascade channels as an example with reference to the accompanying drawings.
As shown in fig. 3, the device for implementing the "flexible electrode dynamic deformation electrochemical machining method" of the present invention mainly comprises a cathode clamping shaft 1, a tool electrode 2, a closed blisk machining workpiece 3, and a workpiece rotating table 4, taking the closed blisk cascade channel electrochemical machining as an example.
The motion form of the invention is shown in fig. 4, a tool electrode 2 is connected on a processing shaft through a cathode clamping shaft 1, the tool electrode 2 is driven to move through the spatial motion of the processing shaft, and corresponding load is applied at the same time; the closed blisk machining workpiece 3 is arranged on a workpiece rotating platform 4, and the closed blisk machining workpiece 3 is driven to rotate through the workpiece rotating platform 4; through the compound motion of the tool electrode 2 and the closed blisk machining workpiece 3, the electrochemical machining gap is controlled, and the sweeping type electrochemical machining which is performed along the surface of the complex profile of the workpiece by taking the side wall of the tool electrode 2 as a machining surface is realized.
Preparation of the tool electrode 2 of the present invention. The tool electrode 2 is made of a metal material having good corrosion resistance, certain rigidity and ductility, and can be bent and deformed when a corresponding load is applied, and when the load is removed, the tool electrode rebounds and is deformed and restored, and the tool electrode is in a slender tubular or rod shape.
The invention relates to the preparation of a closed blisk machining workpiece 3. Before the closed blisk is used for machining the workpiece 3, through holes with equal blade number need to be formed through a mechanical machining method, and the width of each through hole is larger than the diameter of the tool electrode 2.
Because of the deformation and displacement of the tool cathode in the processing process, in order to avoid the unfavorable phenomena of liquid shortage and the like in the processing process, the flow form of the electrolyte is designed to be a lateral flow type, the flow field is an open flow field, namely an electrolyte liquid supply device is additionally arranged, and the electrolyte flows along the axial direction of the tool cathode.
The process of electrolytically machining closed blisk cascade channels using the present invention requires the following ten steps.
The method comprises the following steps: installing a closed blisk processing workpiece 3 on a workpiece rotary table 4, wherein the closed blisk processing workpiece 3 is connected with the anode of an electrolytic processing power supply;
step two: two cathode clamping shafts 1 are vertically arranged on a processing shaft capable of realizing multi-shaft linkage, and the processing shaft is connected with the cathode of an electrochemical machining power supply;
step three: the two cathode clamping shafts 1 are moved through the movement of the machining shafts, so that the axes of the cathode clamping shafts coincide with a certain straight hole formed by the closed blisk machining workpiece 3, and the cathode clamping shafts 1-the closed blisk machining workpiece 3-the cathode clamping shafts 1 are in an 'up-middle-down' form;
step four: the tool electrode 2 penetrates through a through hole of a closed blisk machining workpiece 3, two ends of the tool electrode are respectively connected with the two cathode clamping shafts 1, when the tool electrode 2 is connected, the lower end of the tool electrode is restrained by a fixed end, and the upper end of the tool electrode is restrained by a hinged support;
step five: detecting and correcting the position of the front mounted part;
step six: the tool electrode 2 is moved to the initial position of the blade grid channel blade basin through the relative movement of the processing shaft and the workpiece rotary table 4;
step seven: feeding the machining shaft under the condition of setting parameters of the blade basin surface, applying an initial load, and enabling the tool electrode 2 to generate corresponding bending deformation to reach a preset initial shape;
step eight: electrolyte is introduced, an electrochemical machining power supply is switched on, the tool electrode 2 moves along the radial direction of the closed blisk machining workpiece 3 under the driving of the machining shaft, meanwhile, the machining shaft applies load to the tool electrode 2 under the set parameters of the blisk surface, so that the tool electrode 2 generates dynamic deformation, the closed blisk machining workpiece 3 rotates under the driving of the workpiece turntable 4, and therefore composite motion is generated, and finally machining of the blisk surface of the blade grid channel is completed;
step nine: after the processing of the blade basin surface is finished, the electrolytic processing power supply is disconnected, the electrolyte supply is stopped, the load is removed, the tool electrode 2 is deformed and restored and moves to the blade back of the blade cascade channel, the processing shaft applies an initial load to the tool electrode 2 under the condition of setting the parameters of the blade back, and the tool electrode 2 generates corresponding bending deformation to reach a preset initial shape; electrolyte is introduced, an electrochemical machining power supply is switched on, the tool electrode 2 moves along the radial direction of the closed blisk machining workpiece 3 under the driving of the machining shaft, meanwhile, the machining shaft applies load to the tool electrode 2 under the set blade back parameter, so that the tool electrode 2 generates dynamic deformation, the closed blisk machining workpiece 3 rotates under the driving of the workpiece rotary table 4, and therefore composite motion is generated, and machining of the blade back of the blade cascade channel is finally completed;
step ten: and (3) after the machining is finished, disconnecting the electrolytic machining power supply, stopping the electrolyte supply, removing the load, recovering the deformation of the tool electrode 2, and switching to the next straight hole, and sequentially circulating the steps until all cascade channels of the closed blisk machining workpiece 3 are subjected to electrolytic machining.

Claims (5)

1. The dynamic deformation electrolytic machining method for the flexible electrode is characterized by comprising the following steps of:
adopting tubular or bar-shaped metal which is corrosion-resistant, meets the rigidity requirement, can be bent and deformed when corresponding load is applied, and can be deformed and recovered when the load is removed as an electrolytic machining tool electrode; when the complex profile is machined, the side wall of the tool electrode is used as a machining surface to perform sweep type electrolytic machining along the surface of the complex profile of the workpiece; in the processing process, according to the curvature change characteristics of the profile of the workpiece, by applying different loads, the tool electrode is dynamically deformed while being fed, and the deformed shape of the tool electrode is similar to a mathematical model of the profile line of the workpiece, so that the processed profile of the workpiece is close to an ideal profile, and the specific process is as follows:
step 1, establishing a relation between the deformation curvature of the flexible electrode and the curvature of the profile of the workpiece according to standard profile sampling data of the workpiece to be machined, wherein the mathematical model establishment process is as follows:
step 1-1, sampling the molded surface of a processed workpiece, researching the electrolytic machining forming rule of the molded surface by applying a cos theta method, and simplifying and approximating a complex electric field in an actual machining gap, wherein the method is mainly based on the following assumptions:
(1) the potential gradient along the direction of the current line is unchanged, namely the electric field intensity on the same current line is the same;
(2) from the anode equipotential surface to the cathode equipotential surface, the potential is gradually reduced, and the equipotential surface is orthogonal to the current line;
(3) the conductivity kappa of the electrolyte in the processing gap is uniformly distributed;
1-2, after simplifying approximate treatment, obtaining an equation set related to a forming rule according to the basic principles of electrolytic machining of ohm law and Faraday law:
UR＝U-δE
Figure FDA0003537918650000011
va＝ηωi
in the formula of URIs the voltage drop in the interstitial electrolyte; u is the voltage between the cathode and the anode; delta E is the sum of the potential values of the cathode and the anode electrodes; i is the current density; kappa is the electrolyte conductivity; delta is the machining gap; v. ofaThe workpiece electrolysis speed; η is the current efficiency; omega is volume electrochemical equivalent;
step 1-3, when the electrolytic machining reaches an equilibrium state, the electric field parameters do not change along with time, but only are functions of spatial positions, namely, the gap electric field is a stable and constant electric field; establishing related workpiece electrolysis speed v according to ohm law and Faraday lawaThe basic equation of (1): v. ofaAnd (3) deriving a calculation formula of the machining gap delta by a simultaneous equation set:
Figure FDA0003537918650000021
in the formula: v is the cathode feed speed; theta is an included angle between the normal direction of the profile of the workpiece and the feeding direction of the cathode; deltabMachining the gap for balance;
step 1-4, because the tool cathode is a slender tubular or rod-shaped electrode and carries out sweep type electrolytic machining, the tool cathode is simplified into a two-dimensional curve, and the sweep process of the curve is the profile of the machined workpiece; therefore, in the dynamic deformation process of the flexible electrode, the coordinate relationship between each point of the flexible electrode, namely the cathode of the tool, and the corresponding sampling point of the profile of the workpiece is as follows:
x＝xa-Δcosα
y＝ya-Δcosβ
in the formula: x and y are coordinate values of a certain point on the cathode profile of the tool, xaAnd yaThe coordinate values of the corresponding workpiece profile sampling points are shown, and alpha and beta are respectively included angles between the workpiece profile sampling points and coordinate axes X and Y;
step 1-5, performing polynomial fitting on the obtained coordinate values of the tool cathode profile to obtain a functional relation between y and x:
Figure FDA0003537918650000022
in the formula: k is the order of the polynomial, t0,…,tKIs a polynomial coefficient, denoted as T;
step 1-6, obtaining the curvature of each point of the flexible electrode in the dynamic deformation process of the flexible electrode according to the curvature formula and the function relation of y and x obtained in the step 1-5:
Figure FDA0003537918650000023
in the formula: y (x) 'is the first derivative of y (x, T), and y (x)' is the second derivative of y (x, T);
step 2, determining the size of the load required in the dynamic deformation sweep type electrochemical machining process of the flexible electrode by combining the relation between the deformation curvature of the flexible electrode and the load; the relation between the deformation curvature of the flexible electrode and the borne load is established through the following mathematical model:
step 2-1, after the tool cathode is installed, simplifying the tool cathode into a simply supported beam model with one end constrained by a fixed end, one end hinged and the length of l, wherein the boundary condition is that the deflection is 0 under the constraint condition of the hinged position, and establishing a coordinate system taking the length direction of the tool cathode as an X axis and the radial direction of the section of the tool electrode as a Y axis;
step 2-2, under the condition that shear stress is neglected in pure bending deformation and transverse force bending deformation, the relation between bending moment and curvature is as follows:
Figure FDA0003537918650000031
wherein ρ is the curvature, M is the applied load, E is the elastic modulus of the material, I is the moment of inertia, and EI is its bending stiffness; calculating an approximate differential equation for the available deflection line:
Figure FDA0003537918650000032
wherein w is deflection;
step 2-3, the angular displacement of the cross section to the original position is called as the corner of the cross section, and according to a corner equation:
Figure FDA0003537918650000033
calculating to obtain: EIw ═ m (x) dx + C, where γ is the angle of rotation, w' is the first derivative of deflection, and C is the integral constant;
step 2-4, integrating the above formula to obtain a deflection equation:
Figure FDA0003537918650000034
further simplifying as follows: EIw ═ jjj (m (x) dx) dx + Cx + D, where w is the deflection and C, D are integral constants;
and 2-5, substituting the boundary conditions into the formula to obtain a deflection equation:
Figure FDA0003537918650000035
wherein M is the applied load, l is the length of the tool electrode, and x is the abscissa of any point of the tool electrode;
and 2-6, obtaining the curvature of the point at any point according to a curvature formula:
Figure FDA0003537918650000036
wherein
Figure FDA0003537918650000037
w' is the first derivative of the deflection,
Figure FDA0003537918650000038
w "is the second derivative of deflection;
step 3, obtaining the change of the flexible electrode curvature corresponding to the workpiece profile in the machining process according to a flexible electrode deformation curvature and workpiece profile model established according to the standard profile sampling data of the machined workpiece, and obtaining the change of the load borne by the flexible electrode in the machining process according to the relation between the flexible electrode deformation curvature and the load borne by the flexible electrode;
and calculating by combining the two models to obtain the applied load, so that the flexible electrode realizes the dynamic deformation of the standard molded surface of the fitting machining workpiece in the sweeping type machining process.
2. The flexible electrode dynamic deformation electrolytic machining method according to claim 1, characterized in that: because of the deformation and displacement of the tool electrode in the machining process, in order to avoid the unfavorable phenomenon of a liquid shortage area in the machining process, the flow form of the electrolyte is a lateral flow type, the flow field is an open type or a semi-closed type flow field, and the electrolyte flows along the axial direction of the tool cathode through an additional electrolyte supply device.
3. The flexible electrode dynamic deformation electrolytic machining method according to any one of claims 1 to 2 is applied to part machining with a variable cross-section profile, and is characterized in that: installing the tool electrode and the processing workpiece, reasonably adjusting the position relation of the tool electrode and the processing workpiece, applying different loads according to the curvature change characteristics of the processed variable cross-section profile part, and enabling the tool electrode to realize dynamic deformation of the fit standard profile in the sweeping type processing process, so that the processed workpiece profile is close to the ideal profile, and the processing of the part with the variable cross-section profile is completed.
4. The flexible electrode dynamic deformation electrolytic machining method is applied to part machining with a variable cross-section profile, and is characterized in that: the method is particularly applied to machining of the closed blisk, straight holes with equal blade number are pre-opened on the blank of the closed blisk according to the blade distribution positions, and tool electrodes are convenient to mount; in the pre-through straight hole, a complex twisted channel of the closed blisk is processed in a sweep type electrolytic processing mode of controllable dynamic deformation of the flexible electrode.
5. The flexible electrode dynamic deformation electrolytic machining method is applied to part machining with a variable cross-section profile, and is characterized in that: the method is particularly applied to electrolytic machining of closed blisk cascade channels, and is characterized in that: the tool electrode (2) is connected to the processing shaft through the cathode clamping shaft (1), and the tool electrode (2) is driven to move through the spatial movement of the processing shaft and applies corresponding load; the closed blisk machining workpiece (3) is arranged on the workpiece rotating platform (4), and the closed blisk machining workpiece (3) is driven to rotate through the workpiece rotating platform (4); through the compound motion of the tool electrode (2) and the closed blisk machining workpiece (3), the electrochemical machining gap is controlled, and the sweeping type electrochemical machining which is performed along the surface of the complex profile of the workpiece by taking the side wall of the tool electrode (2) as a machining surface is realized.
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