超声扰动在微孔电解加工中作用机理的研究

Basic research on mechanism of ultrasonic disturbed electrolyte in micro electrochemical machining

深入分析了超声扰动电解液在微孔电解加工中的作用机理,提出了超声空化效应是引起加工间隙内电解液流场参数分布发生变化的主要因素。借助有限元分析软件COMSOL Multiphysics建立加工间隙区内声场的仿真模型,对声压的分布变化进行分析求解。通过对仿真结果的分析,验证了超声扰动作用在加工间隙区域内存在空化效应。进行了微孔电解加工实验,比较了不同频率的超声波对加工间隙区域的作用效果,结果显示:在一定范围内的低频率超声扰动更容易在加工间隙区域中形成超声空化,更有利于提高微孔电解加工的精度。

The mechanism of uhrasonic disturbed electrolyte micro-ECM was analyzed. It is proposed that the distribution of electrolyte flow parameters will be improved by ultrasonic cavitation. With the simulation software COMSOL Multiphysics, the effect of sound field parameters was calculated in detail. By analyzing the simulation results, ultrasound of frequency 20kHz and intensity 1.13 ×10^5 Pa was used to induce cavitation in electrolyte region. In the end, the mechanism of ultrasonic cavitation was detected and micro-hole experiments were performed. The results showed that the cavitation is exist when electrolyte is disturbed by lowfrequency ultrasound in inter-electrode gap, and the machining velocity and accuracy will be improved with the electrolyte disturbed by ultrasound.