异形深孔电解加工过程的流场优化

Flow Field Optimization in Electrochemical Machining Process of Special-shaped Deep Holes

针对异形深孔电解加工过程中进出口流场突变现象、加工间隙流场分布不均、工艺稳定性相对较差等问题,以深径比12∶1的异形孔零件为研究对象,对加工开始、加工稳定、加工穿透各个阶段流场分布进行仿真优化研究。通过导流结构、多孔通液阴极结构保证电解加工进出口流场平稳性;采用合理的电解液压力、复合进给加工模式等措施改善流场分布均匀性,避免空穴现象。基于流场仿真优化结果,开展了异形深孔连续电解加工试验,孔尺寸精度可控制在0.03 mm。

Aiming at the problems of sudden change of inlet and outlet flow fields,uneven distribution of flow fields in machining gaps and poor process stability during the electrochemical process of special-shaped deep holes,the special-shaped hole parts with a depth-diameter ratio of 12∶1 were taken as the research object,simulation and optimization of the flow field distribution were studied at processing start,processing stability and processing penetration.The flow structure and porous cathode structure were used to ensure the stability of the flow field inlet and outlet at the electrochemical machining.Reasonable electrochemical pressure and compound feed mode were adopted to improve the uniformity of the flow field distribution and also avoid cavitation.Based on the simulation and optimization results of the flow field,a continuous electrochemical machining test for special-shaped deep holes was carried out,and the hole size accuracy can be controlled at 0.03 mm.