脊状结构组合式轮片状阴极工作齿齿形优化设计

The Optimization of Assembled Turntable Working Teeth Cathode Profile with Riblet Surface

针对组合式轮片状阴极工作齿(TWTC)齿形优化设计,研究脊状结构的形状参数与减阻量之间的关系。根据湍流边界层粘性底层流速服从线性分布的规律,利用粘性底层流速分布公式来计算流场特性参数,提出将脊状结构、圆角过渡用于组合式TWTC齿形修形。对未修形、脊状结构、圆角过渡组合式TWTC修形的电解加工间隙流场进行仿真和试验验证。结果表明:采用脊状结构修形工作齿可以有效减小电解液流道的阻力,提高加工间隙电解液的流速,使加工间隙最高流速从42.5 m/s提高到58.6 m/s,加速了阳极溶解速度,提高了材料去除率;采用圆角过渡修形工作齿能够减少、甚至避免空穴、涡流、分离、气泡现象产生,实现均匀小间隙稳定深孔内螺旋线加工,提高加工精度和表面质量。

The relation between shape parameter and drag reduction of the riblet surface is discussed to optimize the teeth profile of assembled turntable working teeth cathode （TWTC）. According to the linear distributing law to which the flow velocity in viscous sublayer of turbulence boundary layer submits, the characteristic parameters of flow field are calculated by the formula of flow velocity in viscous sublayer, and then a scheme of using the riblet surface and transition fillets for working-teeth is investigated. The flow field in the machining gap of the un-optimized TWTC with riblet surface and transition fillets is veri- fied by simulation and experiments. The results show that the assembled TWTC with riblet surface greatly reduces the resistance of electrolyte flow channel and increases the maximum flow velocity of electrolyte in the machining gap from 42.5 m/s to 58.6 m/s. Meanwhile, it boosts anodic dissolution rate as well as material removal rate of electrochemical machining. The cavitations, eddy flow, separation and bubble can be decreased and even avoided using the transition fillets between working teeth, which realize the stable machining of internal spiral line in the uniformed gap and improve the machining accuracy and surface quality of electrochemical machining.