CN115846778A - Discharge electrochemical-grinding sequential circulation combined machining tool electrode and machining method - Google Patents
Discharge electrochemical-grinding sequential circulation combined machining tool electrode and machining method Download PDFInfo
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Abstract
The invention relates to a discharge electrochemistry-grinding sequence circulation combined machining tool electrode and a machining method, and belongs to the field of combined machining. The invention provides a discharge-electrochemical composite cooperative grinding method, wherein the discharge-electrochemical action and the grinding action are alternately acted on a workpiece material, and the processing sequence comprises discharge electrochemical rough machining, grinding rough machining, discharge electrochemical finish machining and grinding finish machining in sequence, so that the high-efficiency precision machining of the profile of the workpiece is realized, the machining error caused by the replacement of a tool electrode is avoided, and meanwhile, the motion of the tool electrode is coupled with the pulse power supply application mode and the pulse power supply parameters, so that the output of invalid power is avoided, the energy utilization rate is improved, and the higher processing efficiency is favorably obtained. Meanwhile, the tool electrode adopts a combined clamping mode, different electrode parts can be assembled and disassembled, the electrode body does not need to be replaced, and the processing cost is reduced.
Description
Technical Field
The invention relates to a discharge electrochemistry-grinding sequence circulation composite machining tool electrode and a machining method, and belongs to the field of composite machining.
Background
With the development of aerospace industry, the demand for aerospace structural members made of difficult-to-process materials such as high-temperature alloys, titanium alloys and composite materials is increasing. For example, the 'melting number' car body bearing structure, the mechanical movement mechanism, the detector structure and other dozens of parts of the Chinese mars car adopt SiC with different silicon carbide contents p The wings, the central wings, the fuselage skin and the like of the C919 airplane are all made of titanium alloy materials, and the F110, F404 and F414 engines are made of Hastelloy X nickel-based high-temperature alloy. However, when the traditional mechanical cutting method is adopted to process such difficult-to-process materials, the defects of low processing efficiency, serious tool abrasion, poor processing surface quality and the like exist, and further popularization and application of the difficult-to-process materials in the aerospace field are limited.
The electric discharge machining is to erode the workpiece material based on the electric erosion phenomenon generated during the spark discharge between the tool electrode and the workpiece, and has the characteristics of high machining efficiency, no macroscopic cutting force during machining and the like. Only when the machining gap reaches dozens of microns, spark discharge can be generated in the machining gap, a large number of spark discharge products can be generated in the machining process, and the spark discharge products are accumulated in the machining gap, so that the working fluid in the gap cannot be quickly restored to the initial dielectric state, the stable proceeding of the spark discharge is influenced, and the efficiency of the discharge machining and the surface quality of a workpiece are reduced.
The electrochemical machining is based on the electrochemical anode dissolution principle, realizes the forming machining process of workpiece materials, and has the characteristics of high machining surface quality, no residual stress on the surface and the like. However, compared with the electric discharge machining, the material removal rate of the electrolytic machining is low, and can only reach hundreds of mm 3 Min, the manufacturing requirement of efficient processing of large structural parts is difficult to meet; compared with grinding machining, the electrochemical machining surface has serious stray corrosion, the machining localization is poor, and higher machining precision cannot be ensured.
The grinding processing is to remove the workpiece material by utilizing the micro-cutting action of micro-abrasive grains in the grinding wheel on the surface of the workpiece, and has the characteristics of high processing precision, good surface quality and the like. The grinding is a finish machining process and is usually used as the final stage of part machining, so the machining allowance of the grinding is small, the material removal rate of the grinding is low, and the manufacturing requirement of high-efficiency machining of large structural parts cannot be met.
Therefore, in order to meet the demand for efficient and precise manufacturing of difficult-to-machine material members rapidly developed in the aerospace field, an innovative machining method that combines machining efficiency and surface quality is urgently needed.
Disclosure of Invention
In order to obtain higher processing efficiency and better surface quality, the invention provides a discharge electrochemical-grinding sequential cycle composite processing tool electrode and a processing method.
An electro-discharge chemical-grinding sequence circulation combined machining tool electrode is characterized in that: the tool electrode is a hollow revolving body electrode, and comprises a discharge-electrochemical rough machining electrode, a rough grinding sheet, a discharge-electrochemical finish machining electrode, a finish grinding sheet and a tool electrode body, wherein the radiuses of all parts are R respectively 1 、R 2 、R 3 、R 4 And R 0 And the radius relationship is R 0 ＜R 3 ＜R 1 ＜R 4 ＜R 2 (ii) a The discharge-electrochemical rough machining electrode, the rough grinding chip, the discharge-electrochemical fine machining electrode and the fine grinding chip respectively have beta corresponding central angles 1 、β 2 、β 3 And beta 4 The central angle corresponding to each part is less than or equal to 90 degrees, and the corresponding central angle is adjustable.
The machining method using the tool electrode is characterized by comprising the following steps: the method comprises the following steps: the tool electrode rotates around the axis for a period T 0 In a period T 0 The whole processing process is divided into four stages, namely a discharging-electrochemical rough machining stage, a rough grinding stage and a discharging-electrochemical fine machining stageA processing stage and a fine grinding stage. In a period T 0 The action time of the internal, discharging-electrochemical rough machining stage, the rough grinding stage, the discharging-electrochemical fine machining stage and the finish grinding stage is t a 、t b 、t c 、t d . 1/2T before tool electrode movement 0 Periodically, the pulse power supply sends out pulse voltage with long pulse width and small amplitude, and the pulse width T 1_on And a pulse interval T 1_off And tool electrode rotation period T 0 Is in accordance with the expression T 1_on +T 1_off ≤1/2T 0 (ii) a After 1/2T of tool electrode movement 0 Periodically, the pulse power supply sends out pulse voltage with short pulse width and large amplitude, and the pulse width T of the pulse voltage 2_on And a pulse interval T 2_off And tool electrode rotation period T 0 Is in accordance with the expression T 2_on +T 2_off ≤1/2T 0 And conforms to the expression T 2_on ＜T 1_on And the pulse voltage amplitude U is long pulse width 1 Less than the short pulse width pulse voltage amplitude U 2 (ii) a Step two: the workpiece is connected with the positive electrode of the pulse power supply, the tool electrode is connected with the negative electrode of the pulse power supply, the tool electrode rotates anticlockwise at high speed in a preset rotating direction, the tool electrode feeds in a direction close to the workpiece along the preset feeding direction, and working liquid is sprayed out from a liquid outlet seam on the side wall of the tool electrode and enters a machining gap between the tool electrode and the workpiece; step three: in the discharging-electrochemical rough machining stage, the tool electrode rotates for 1/4 turn around the axis, the discharging electrochemical rough machining electrode completely enters a machining area, meanwhile, the pulse power supply sends out a plurality of pulse voltages with long pulse widths and small amplitudes, a plurality of times of high-energy spark discharge and violent electrochemical dissolution reactions are generated between the discharging electrochemical rough machining electrode and a workpiece, and a large amount of machining products and hydrogen bubbles are generated in the machining area; the fine grinding sheet has a grinding effect on the surface subjected to discharge electrochemical fine machining, and a grinding product is generated in a machining area, so that the effect of finishing the surface of a workpiece is achieved; step four: in the rough grinding stage, the tool electrode rotates for 1/4 turn around the axis, the rough grinding chips in the tool electrode all rotate into the machining area, and the grinding effect is generated on the machined surface of the discharge electrochemical rough machining electrode, so that a large amount of grinding powder is generatedGrinding the product; meanwhile, the pulse power supply continuously sends out pulse voltage with long pulse width and small amplitude, multiple times of high-energy spark discharge is generated in the machining gap between the discharge electrochemical rough machining electrode and the workpiece, and a large amount of workpiece materials are quickly eroded by the spark discharge and electrochemical dissolution; step five: in the discharging-electrochemical finishing stage, the tool electrode continuously rotates around the axis by 1/4, the discharging-electrochemical finishing electrode in the tool electrode completely enters a machining area, meanwhile, the pulse power supply sends out a plurality of pulse voltages with short pulse widths and large amplitude, and a plurality of times of low-energy spark discharges and weaker electrochemical dissolution reactions are generated between the discharging-electrochemical finishing electrode and a workpiece to generate a small amount of machining products and hydrogen bubbles; the rough grinding chips have a grinding effect on the surface after discharge-electrochemical rough machining, and a large amount of grinding products are generated in a machining area, so that the effects of removing workpiece materials in a large amount and finishing the surface of a workpiece are achieved; step six: in the fine grinding stage, the tool electrode continuously rotates around the axis for 1/4 of a turn, the fine grinding blades in the tool electrode all rotate to enter a machining area, and the grinding action is started to be generated on the surface of the workpiece machined by the discharge-electrochemical finish machining electrode, so that the effect of finishing the surface of the workpiece is achieved; meanwhile, the pulse power supply continuously sends out a plurality of pulse voltages with short pulse width and large amplitude, a plurality of times of low-energy spark discharge is generated in the discharge-electrochemical rough machining electrode and the workpiece machining gap, and the workpiece material is corroded and removed by the low-energy spark discharge and electrochemical dissolution; step seven: and continuously repeating the third step to the sixth step along with the continuous feeding of the tool electrode, and realizing the efficient and precise machining of the workpiece material under the intermittent spark discharge action, the electrolysis action and the grinding action.
Compared with single electric spark machining, electrolytic machining or grinding machining, the discharge electrochemical-grinding sequential cycle combined machining tool electrode and the machining method can be used for efficiently performing rough machining and finish machining on a workpiece by using the same tool, so that efficient and precise machining on the workpiece material is realized, positioning errors caused by replacement of the tool electrode are avoided, and the machining precision and the machining efficiency of the workpiece are improved. Different processing effects can be obtained by adjusting the discharge-electrochemical combined machining rough and finish machining electrode and the grinding rough and finish machining grinding head corresponding to the central angle. The discharge-electrochemical combined machining rough machining electrode and the corresponding central angle of the rough grinding chip are increased, so that higher machining efficiency can be obtained; the corresponding central angle of the discharge electrochemical combined machining fine machining electrode and the fine grinding blade is increased, and better surface quality can be obtained. The discharge electrochemical-grinding sequential circulation combined machining tool electrode comprises a discharge electrochemical rough machining electrode, a discharge electrochemical fine machining electrode, a rough grinding sheet and a fine grinding sheet, a tool electrode body is connected with each electrode through a bolt, and after machining is finished, the used discharge electrochemical-machining electrode can be detached and replaced, so that low-cost, high-machining efficiency and high-quality rough and fine integrated machining can be realized. The motion of the tool electrode is coupled with the application mode of the pulse power supply, and the pulse power supply sends different types of pulse voltages at different processing stages, so that the power requirement of the pulse power supply is reduced, the utilization efficiency of the power supply is improved, and the output of ineffective energy is avoided.
The discharge electrochemistry-grinding sequence circulation composite machining tool electrode and the machining method are characterized in that: the tool electrode body is made of stainless steel, the discharging-electrochemical rough machining electrode and the discharging-electrochemical finish machining electrode are made of graphite or copper-tungsten alloy or red copper, the base materials of the rough grinding sheet and the finish grinding sheet (13) are resin-based or ceramic-based materials, and the reinforced phase abrasive grain material is diamond, CBN, siC or Al 2 O 3 Grinding materials, wherein the granularity of the coarse grinding materials in the coarse grinding sheet is 40# to 280#, and the granularity of the fine grinding materials in the fine grinding sheet is 400# to 1500#; and the workpiece material is titanium alloy or high-temperature alloy or stainless steel or metal matrix composite material. The rough grinding chips and the finish grinding chips adopt grinding materials with different meshes, so that rough machining and finish machining of a machining area can be realized more efficiently, machining efficiency is improved, and surface quality is improved.
The discharge electrochemistry-grinding sequence circulation composite machining tool electrode and the machining method are characterized in that: the working solution is sodium nitrate or sodium chloride solution, and the concentration is not lower than 5%.
With the salt solution with higher concentration, a large amount of bubbles exist in the processing process, and aggregate polymerization and form an air film, thereby causing spark discharge; meanwhile, the high-concentration salt solution is adopted, so that the electrolytic machining current is favorably improved, and the material removal rate is improved.
The discharge electrochemistry-grinding sequence circulation combined machining tool electrode and the machining method are characterized in that: the diameter of the bottom area of the tool electrode body is 15-60mm.
The discharge electrochemistry-grinding sequence circulation composite machining tool electrode and the machining method are characterized in that: the pulse voltage with long pulse width and small amplitude is 10V-40V, the pulse width is 500us-10ms, the short-pulse width and large-amplitude pulse voltage is 40-120V, and the pulse width is 10-300 us.
After the discharge-electrochemical combined machining rough machining electrode is cut into a machining area, a pulse power supply sends out pulses with pulse voltage of 10V-40V and pulse width of 500us-10ms, multiple times of high-energy spark discharge is generated in the machining area, the electrochemical dissolution effect is stronger, and sufficient energy input is provided for machining and removing materials; when the discharge electrochemical combined machining finish machining electrode is cut into a machining area, the pulse power supply sends out a plurality of pulses with the pulse voltage of 40-120V and the pulse width of 10-300 us, multiple times of spark discharge with small energy is generated in the machining area, the electrochemical dissolution effect is weak, the effect of finishing the surface quality of a rough machined workpiece is achieved, meanwhile, under the impact effect of a spark discharge channel, machining products generated in the rough machining stage in the machining area are removed, and the machining efficiency is improved.
Drawings
FIG. 1 is a schematic diagram of a cut-in discharge-electrochemical machining cooperative grinding discharge-electrochemical machining rough machining start position according to the present invention;
FIG. 2 is a schematic diagram of a rough grinding start position of plunge electric discharge-electrochemical hybrid cooperative grinding according to the present invention;
FIG. 3 is a schematic diagram of a cut-in discharge-electrochemical combined machining discharge-electrochemical combined finishing start position according to the present invention;
FIG. 4 is a schematic diagram of a cutting-in type electric discharge-electrochemical combined grinding fine grinding start position according to the present invention;
FIG. 5 is a schematic cross-sectional view of a plunge electric discharge-electrochemical hybrid collaborative grinding tool electrode;
FIG. 6 is a schematic diagram of the coupling of the rotational movement of the tool electrode to the pulse application;
FIG. 7 is a three-dimensional schematic view of a plunge electric discharge-electrochemical composite collaborative grinding tool electrode;
the number designations in the figures are: 1. electro-discharge electrochemical rough machining an electrode; 2. a working fluid; 3. processing the product; 4. coarse abrasive grains; 5. a pulse power supply; 6. roughly grinding and chipping; 7. discharging the electrochemical finish-machining electrode; 8. grinding the product; 9. spark discharge; 10. a workpiece; 11. a tool electrode body; 12. fine abrasive grains; 13. finely grinding the slices; 14. the direction of rotation; 15. hydrogen bubbling; 16. a direction of feed; 17. and (6) discharging liquid from the liquid gap.
Detailed Description
The present invention is described in further detail below with reference to the specific drawings.
Fig. 1 is a schematic diagram of a starting position of plunge electric discharge-electrochemical hybrid cooperative abrasive machining electric discharge-electrochemical hybrid rough machining. The tool electrode 11 rotates counterclockwise at a high speed according to a preset rotating direction 14 and feeds at a constant speed along a feeding direction 16, a 1/2 section of the discharging-electrochemical rough machining electrode 1 rotates to enter a machining area, the pulse power supply 5 starts to emit a plurality of pulse voltages with long pulse widths and small amplitudes, and the radius R of the discharging-electrochemical rough machining electrode 1 is 1 Is larger than the radius R of the discharge-electrochemical finish machining electrode 7 3 Therefore, the machining gap between the discharge-electrochemical rough machining electrode 1 and the workpiece 10 is smaller than the machining gap between the discharge-electrochemical finish machining electrode 7 and the workpiece 10, and therefore the spark discharge 9 generated between the discharge-electrochemical rough machining electrode 1 and the workpiece 10 has greater energy and stronger electrochemical dissolution; with the feeding of the tool electrode 11, the fine grinding blade 13 trims the surface of the discharge-electrochemical finish machining electrode 7 after machining, removes a surface defect layer and improves the surface quality of the workpiece 10;
fig. 2 is a schematic view of a rough grinding start position in plunge electric discharge-electrochemical hybrid collaborative grinding. The tool electrode 11 rotates anticlockwise at high speed in a preset rotating direction 14 and feeds at a constant speed in a feeding direction 16, 1/2 section of the rough grinding chip 6 rotates to enter a machining area, the surface of the workpiece 10 machined by the discharge-electrochemical rough machining electrode 1 is trimmed, and a surface defect layer is removed; the pulse power supply 5 continuously sends out a plurality of pulse voltages with long pulse width and small amplitude, and intense spark discharge 9 and electrochemical dissolution reaction are generated between the discharge-electrochemical rough machining electrode 1 and the workpiece 10, so that the workpiece material is efficiently etched away;
fig. 3 is a schematic diagram of a cut-in discharge-electrochemical composite collaborative grinding discharge-electrochemical composite finishing start position. The tool electrode 11 rotates counterclockwise at a high speed according to a preset rotating direction 14 and feeds at a constant speed along a feeding direction 16, 1/2 section of the discharging-electrochemical finishing electrode 7 rotates to enter a processing area, the pulse power supply 5 starts to emit a plurality of pulse voltages with short pulse width and large amplitude, and the radius R of the discharging-electrochemical finishing electrode 7 is caused 3 Less than radius R of discharge-electrochemical rough machining electrode 1 1 Therefore, the machining gap between the discharge-electrochemical finishing electrode 7 and the workpiece 10 is larger than the machining gap between the discharge-electrochemical rough machining electrode 1 and the workpiece 10, so that the spark discharge 9 generated between the discharge-electrochemical finishing electrode 7 and the workpiece 10 has smaller energy and weaker electrochemical dissolution, and only has the effect of improving the surface quality; the rough grinding particles 4 in the rough grinding chip 6 are in contact with the workpiece 10 material, so that the surface defect layer and the base material after the discharge-electrochemical rough machining electrode 1 is machined are removed, and the machining efficiency is improved.
FIG. 4 is a schematic diagram of a finish grinding starting position of plunge electric discharge-electrochemical combined grinding machining. The tool electrode 11 rotates at a high speed anticlockwise in a preset rotating direction 14 and feeds at a constant speed in a feeding direction 16, the pulse power supply 5 continuously sends out a plurality of pulse voltages with short pulse widths and large amplitude, the spark discharge 9 and the electrochemical dissolution reaction generated between the discharge-electrochemical finish machining electrode 7 and the workpiece 10 are weak, and the machining surface quality is improved; 1/2 section of the fine grinding sheet 13 rotates to enter a machining area, and the surface of the workpiece machined by the discharge-electrochemical fine electrode 7 is trimmed, so that the surface quality is improved;
FIG. 5 is a schematic cross-sectional view of a plunge electric discharge-electrochemical hybrid collaborative grinding tool electrode. Discharge-electrochemical rough machining electrode 1, discharge-electrochemical finish machining electrode 7, rough grinding chip 6, finish grindingThe radius of the sheet 13 and the body of the tool electrode 11 are R 1 、R 3 、R 2 、R 4 And R 0 And the radii of the portions have a relationship R 0 ＜R 3 ＜R 1 ＜R 4 ＜R 2 The radius difference is 0.1mm-0.5 mm; the discharging-electrochemical rough machining electrode 1, the rough grinding sheet 6, the discharging-electrochemical finish machining electrode 7 and the finish grinding sheet 13 are respectively beta corresponding to central angles 1 、β 2 、β 3 And beta 4 By adjusting the corresponding central angle of each part, the action time of different electrodes or grinding sheets can be controlled, different processing effects can be obtained, and the beta is increased 1 And beta 2 Can obtain higher processing efficiency and increase beta 3 And beta 4 Better surface quality can be obtained;
fig. 6 is a schematic diagram of the coupling of the tool electrode rotational motion and the pulse application mode. The rotation period of the tool electrode 11 is T 0 And t is and t a ＝t b ＝t c ＝t d ＝1/4T 0 The rotation period of the tool electrode 11 is several tens milliseconds to several hundreds milliseconds; pulse width T of long-pulse width and small-amplitude pulse voltage 1_on And a pulse interval T 1_off And the rotation period T of the tool electrode 11 0 Is in accordance with the expression T 1_on +T 1_off ≤1/2T 0 ，T 1_on The value is from several milliseconds to tens of milliseconds; pulse width T of short-pulse width and large-amplitude pulse voltage 2_on And a pulse interval T 2_off And tool electrode rotation period T 0 Is in accordance with the expression T 1_on +T 1_off ≤1/2T 0 And conforms to the expression T 2_on ＜T 1_on ，T 2_on The value is from microseconds to tens of microseconds; long pulse width pulse voltage amplitude U 1 Less than the short pulse width pulse voltage amplitude U 2 Long pulse width pulse voltage amplitude U 1 20-70V and U 1 Amplitude less than U 2 The amplitude is 20-70V.
FIG. 7 is a three-dimensional schematic view of a plunge electric discharge-electrochemical hybrid collaborative grinding tool electrode. The discharge-electrochemical combined grinding machining tool electrode consists of a discharge-electrochemical rough machining electrode 1, a discharge-electrochemical finish machining electrode 7, a rough grinding chip 6, a finish grinding chip 13 and a tool electrode 11 body, wherein the electrodes are embedded in the tool electrode 11 body in a bolt connection mode, the tool electrode 11 body is provided with a working fluid 2 flow channel, and the bottom of the tool electrode is provided with a liquid outlet slot 17.
The plunge type discharge-electrochemical combined grinding in-situ high-efficiency precision machining method provided by the invention expands the application range of the discharge-electrochemical combined machining technology, but the above description cannot be understood as the limitation of the invention. It should be noted that several improvements can be made without departing from the inventive concept, which shall all fall within the protection of the present patent.
Claims (6)
1. An electro-discharge chemical-grinding sequence circulation combined machining tool electrode is characterized in that:
the tool electrode (11) is a hollow revolving body electrode, and comprises a discharge-electrochemical rough machining electrode (1), a rough grinding sheet (6), a discharge-electrochemical finish machining electrode (7), a finish grinding sheet (13) and a tool electrode (11) body;
the radius of each part is R 1 、R 2 、R 3 、R 4 And R 0 And the radius relationship is R 0 ＜R 3 ＜R 1 ＜R 4 ＜R 2 ；
The discharging-electrochemical rough machining electrode (1), the rough grinding chip (6), the discharging-electrochemical finish machining electrode (7) and the finish grinding chip (13) respectively have beta corresponding central angles 1 、β 2 、β 3 And beta 4 The central angle corresponding to each part is less than or equal to 90 degrees, and the corresponding central angle is adjustable.
2. A method of machining with a tool electrode according to claim 1, comprising the steps of:
the method comprises the following steps: the tool electrode (11) rotates around the axis for one circle with a period T 0 In a period T 0 The discharging-electrochemical rough machining electrode (1), the rough grinding chip (6), the discharging-electrochemical finish machining electrode (7) and the finish grinding chip (13) act alternately in turn,the whole processing process is divided into four stages, namely a discharging-electrochemical rough processing stage, a rough grinding stage, a discharging-electrochemical fine processing stage and a fine grinding stage; in a period T 0 The action time of the internal, discharging-electrochemical rough machining stage, the rough grinding stage, the discharging-electrochemical fine machining stage and the finish grinding stage is t a 、t b 、t c 、t d (ii) a Before the tool electrode (11) moves for 1/2T 0 Periodically, the pulse power supply (5) sends out a pulse voltage with long pulse width and small amplitude, and the pulse width T 1_on And a pulse interval T 1_off With the rotation period T of the tool electrode (11) 0 Is in accordance with the expression T 1_on +T 1_off ≤1/2T 0 (ii) a After 1/2T of tool electrode (11) movement 0 Periodically, the pulse power supply (5) sends out pulse voltage with short pulse width and large amplitude, and the pulse width T of the pulse voltage 2_on And a pulse interval T 2_off With the rotation period T of the tool electrode (11) 0 Is in accordance with the expression T 2_on +T 2_off ≤1/2T 0 And conforms to the expression T 2_on ＜T 1_on And the pulse voltage amplitude U is long pulse width 1 Less than short pulse width pulse voltage amplitude U 2 ；
Step two: a workpiece (10) is connected with the positive electrode of a pulse power supply (5), a tool electrode (11) is connected with the negative electrode of the pulse power supply (5), the tool electrode (11) rotates anticlockwise at high speed in a preset rotating direction (14), the tool electrode (11) feeds towards the direction close to the workpiece along a preset feeding direction (16), and working liquid (2) is sprayed out from a liquid outlet seam (17) on the side wall of the tool electrode (11) and enters a machining gap between the tool electrode (11) and the workpiece (10);
step three: in the discharge-electrochemical rough machining stage, a tool electrode (11) rotates around an axis for 1/4 revolution, the discharge electrochemical rough machining electrode (1) completely enters a machining area, meanwhile, a pulse power supply (5) sends out a plurality of pulse voltages with long pulse widths and small amplitudes, a plurality of high-energy spark discharges (9) and violent electrochemical dissolution reactions are generated between the discharge electrochemical rough machining electrode (1) and a workpiece (10), and a large amount of machining products (3) and hydrogen bubbles (15) are generated in the machining area; the fine grinding sheet (13) has a grinding effect on the surface subjected to discharge electrochemical fine machining, and a grinding product (8) is generated in a machining area, so that the effect of finishing the surface of the workpiece (10) is achieved;
step four: in the rough grinding stage, the tool electrode (11) rotates for 1/4 of a turn around the axis, the rough grinding chips (6) in the tool electrode (11) all rotate to enter a machining area, and grinding action is started on the machined surface of the discharge electrochemical rough machining electrode (1) to generate a large amount of grinding products (8); meanwhile, the pulse power supply (5) continuously sends out pulse voltage with long pulse width and small amplitude, multiple times of high-energy spark discharge (9) is generated in the machining gap between the discharge electrochemical rough machining electrode (1) and the workpiece (10), and a large amount of workpiece (10) materials are quickly eroded by the spark discharge (9) and the electrochemical dissolution;
step five: in the discharging-electrochemical finishing stage, the tool electrode (11) continuously passes through 1/4 turn around the axis, the discharging-electrochemical finishing electrode (7) in the tool electrode (11) completely enters a machining area, meanwhile, the pulse power supply (5) emits a plurality of short-pulse-width and large-amplitude pulse voltages, and a plurality of times of low-energy spark discharges (9) and weaker electrochemical dissolution reactions are generated between the discharging-electrochemical finishing electrode (7) and the workpiece (10) to generate a small amount of machining products (3) and hydrogen bubbles (15); the rough grinding chip (6) has a grinding effect on the surface after discharge-electrochemical rough machining, and a large amount of grinding products (8) are generated in a machining area, so that the effects of removing the material of the workpiece (10) in a large amount and finishing the surface of the workpiece (10) are achieved;
step six: in the fine grinding stage, the tool electrode (11) continues to rotate around the axis for 1/4 of a turn, the fine grinding blades (13) in the tool electrode (11) all rotate into the machining area, and grinding action is started to be generated on the surface of the workpiece (10) machined by the discharge-electrochemical finishing electrode (7) so as to achieve the effect of finishing the surface of the workpiece (10); meanwhile, the pulse power supply (5) continuously sends out a plurality of pulse voltages with short pulse width and large amplitude, a plurality of times of low-energy spark discharges (9) are generated in the machining gap between the discharge-electrochemical rough machining electrode (1) and the workpiece (10), and the workpiece (10) material is corroded and removed by the low-energy spark discharges (9) and the electrochemical dissolution;
step seven: and (5) continuously repeating the third step to the sixth step along with the continuous feeding of the tool electrode (11), and realizing the efficient and precise machining of the workpiece (10) material under the action of intermittent spark discharge (9), electrolysis and grinding.
3. The processing method according to claim 2, characterized in that: the tool electrode (11) body is made of stainless steel, the discharge-electrochemical rough machining electrode (1) and the discharge-electrochemical finish machining electrode (7) are made of graphite, copper-tungsten alloy or red copper, the base materials of the rough grinding sheet (6) and the finish grinding sheet (13) are resin-based or ceramic-based materials, and the reinforced phase abrasive grain material is diamond, CBN, siC, al 2 O 3 Abrasive, the coarse abrasive (4) in the coarse grinding chip (6) has a grain size of 40# to 280#, and the fine abrasive (12) in the fine grinding chip (13) has a grain size of 400# to 1500#; and the workpiece (10) is made of titanium alloy or high-temperature alloy or stainless steel or metal matrix composite.
4. The processing method according to claim 2, characterized in that: the working solution (2) is sodium nitrate or sodium chloride solution, and the concentration is not lower than 5%.
5. The processing method according to claim 2, characterized in that: the diameter of the bottom area of the tool electrode (11) body is 15-60mm.
6. The processing method according to claim 2, characterized in that: the long pulse width and small amplitude pulse voltage is 10V-40V, the pulse width is 500us-10ms, the short pulse width and large amplitude pulse voltage is 40V-120V, and the pulse width is 10us-300us.
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