一孔两锥复杂型孔的电解加工旋转流场仿真及工艺试验

Rotating Flow Field Simulation and Experiment Study of Electrochemical Machining Complex Tube with One Hole and Two Cones

针对一孔两锥类复杂零件电解加工易短路、流纹大的问题,提出了一种旋转流场电解加工方法,建立间隙流场模型,并对不同出液孔斜角的阴极在加工中的流场进行了仿真分析。仿真表明:出液孔斜角45°的旋转流场可使加工间隙电解液分布更均匀,极大地减少流场低速区。然后,在加工电压10 V、电解液入口压力1.6 MPa、电解液温度30℃、进给速度5 mm/min的条件下,采用优化后的阴极进行了一孔两锥电解加工工艺试验。结果表明:间隙流场仿真能实现电解加工阴极结构优化,可有效缩短阴极研制周期,降低试验成本。

In order to solve the problem that electrochemical machining(ECM) of complex tube with one hole and two cones is easy to short circuit and largen the flow pattern,a rotating flow field ECM method is proposed with and the gap flow field model of one hole and two cones established,and the flow field with different oblique angle of liquid hole is simulated. The simulation shows that rotating flow field with the outlet hole oblique angle 45° can improve the electrolyte distribution in machining gap and greatly reduce the low speed zone. Under the conditions of processing voltage 10 V,electrolyte inlet pressure 1.6 MPa,electrolyte temperature 30 ℃ and cathode feed speed 5 mm/min,the ECM processing of one hole and two cones was carried out by using the optimized cathode. The result shows that the gap flow field simulation can optimize the cathode structure,while shorten cathode design cycle and reduce test cost.