背压正流式恒间隙法电解加工实验研究

Experimental Study on Electrochemical Machining with Constant Interelectrode Gap Using Guiding Forward Flow

以一种可实现恒定加工间隙的方法为对象,设计了电解液背压式正向流动的方式,以提高加工过程的稳定性。采用有限元方法开展了流场仿真研究,优化了出液口结构。分析表明:与开放式正向流动相比,背压式正向流动加工间隙内的流场更均匀稳定。为了验证流场设计的合理性,开展了恒间隙法脉冲电解加工对比实验。结果显示:与开放式正向流动相比,背压式正向流动加工过程的电流波动量从23%下降到4%,加工表面粗糙度值从Ra1.237μm下降到Ra0.608μm。实验结果证明采用背压式正向流动有助于提高恒间隙法电解加工的稳定性和表面质量,为电流效率曲线的精确测定提供了有效途径。

A new electrolyte flow model called guiding forward flow is designed to improve the stability of electrochemical machining process with constant interelectrode gap. The flow mode is analyzed by finite element method and is compared with traditional open forward flow mode. It is shown that the flow field in the interelectrode gap is more stable with guiding forward flow mode. Experimental investigations were carried out with pulse current in order to evaluate the rationality of the flow mode.The result reveals that a smaller fluctuation of machining current and better surface quality could be obtained with guiding forward flow mode. It could be concluded that guiding forward flow mode is in favor of improving the stability of the device with constant interelectrode gap and measurement of current efficiency.