群孔管电极电解加工均流设计及其试验研究

Flow Balance Design and Experimental Investigation on Electrochemical Drilling of Multiple Holes

为提高群孔电解加工的稳定性和成形精度,对群孔管电极电解加工(ECD)的分流腔流场进行了建模分析。通过对分流腔进行数值求解,研究了分流腔电解液的分布规律,并分析得到了影响电解液分流均匀度的主要参数(分流腔直径),进而对其进行了优化设计。基于该优化设计并结合试验得到了适合正流群孔电解加工的分流均匀度系数和相应的尺寸系数。采用优化的分流腔参数和加工参数进行试验,得到了尺寸精度较好的长排孔结构,孔间距5 mm,孔径为(1.03±0.03)mm,其加工过程稳定,无短路现象。通过优化分流腔结构可以提高其分流均匀度,从而使电解孔加工的稳定性显著增加,加工精度提高。

In order to enhance the processing stability and machining accuracy of electrochemical drilling（ECD） on multiple holes,the flow of the electrolyte along the dividing manifold is modeled,and the electrolyte distribution along the dividing manifold is analyzed through the numerical solution of the model.Manifold diameter,which is the main parameter affecting the uniformity of electrolyte distribution,is optimized subsequently.Based on the optimization,experiments are conducted to obtain the uniformity ratio and the corresponding dimension ratio which suit the multiple hole drilling process.With optimized manifold structure and suitable machining parameters,long rows of holes with a spacing of 5 mm and a diameter of（1.03±0.03）mm are machined by multiple electrodes with good stability.Flow uniformity can be enhanced by optimizing the manifold structure,the machining stability and accuracy of ECD process is hence increased.