高转速螺旋电极微细电解钻削加工仿真及试验研究

Simulation and experimental study on micro electrochemical drilling process by using a high speed spiral electrode

航空发动机镍基合金叶片上的深小孔加工一直是航空制造业中难以解决的问题。介绍了一种用于深小孔加工的微细电解高效钻孔工艺。为了研究微细电解钻削加工过程中高转速螺旋微电极对深小孔加工精度和加工效率的影响规律,对加工间隙流场进行了仿真研究。仿真结果表明,一定转速下在电极表面所形成的绝缘气膜,可以极大减小甚至消除孔壁的二次电解作用,大幅提高加工精度;同时,加工区外的新鲜电解液因负压作用被强行压入加工间隙内,强化传质作用明显,可显著提高加工效率。最后,试验验证了以上仿真结论的正确性,表明微细电解高效钻削加工工艺在深小孔加工方面有着巨大的发展潜力和广泛的应用前景。

Fabrication of deep and micro holes on the nickel-based superalloy blade of aero engine has been a difficult problem in the field of aviation manufacturing. An electrochemical drilling process for fabricating deep and micro holes with high efficiency is introduced. In order to study the influences of high speed micro spiral electrode on machining accuracy and machining efficiency, the simulation of the gap flow field are carried out. The simulation results show the gas film with good insulation effect around the electrode can eliminate the second electrolysis of the hole wall and improve the machining accuracy greatly. In addition, the fresh electrolyte outside were forced into the machining area due to the negative pressure. Enhanced mass transfer is performed well, which can improve the machining efficiency significantly. Finally, the simulation results above were verified by the experiments, which shows that the micro electrochemical drilling process for fabricating deep and micro holes has a huge potential and broad application prospects.