方形切缝扭簧电解线切割加工试验研究

Experimental Investigation on Wire Electrode Electrochemical Machining Square Slotted Torsional Spring

方形切缝扭簧广泛用于各类战机、直升机配平舵机,其力学特性受制造精度影响显著。提出采用低速旋转+直线进给的组合运动方式进行方形扭簧电解线切割加工,分析其组合运动学特性,设计专用运动装置,建立了方形切缝扭簧电解线切割加工试验系统。首先开展穿丝孔管电极电解加工试验研究,探究进给速度和加工电压参数对穿丝孔孔径大小与孔型的影响,选择进给速度0.6mm/min、加工电压14V的加工参数加工出孔径为0.96mm的阵列穿丝孔。其次采用涂覆绝缘涂层的工艺,避免了电解线切割过程中扭簧非加工表面腐蚀现象,同时试验探究了加工电压对其进给速度的影响。最后,采用优化后的工艺参数和改进的工艺流程,加工出平均缝宽为1.006mm、尺寸偏差在±0.05mm内、表面质量较好的方形切缝扭簧样件。

Square slit torsion springs are widely used in various types of fighters and helicopters to trim steering gears,and their mechanical properties are significantly affected by manufacturing accuracy.Combination of low-speed rotation and linear feed to perform wire electrochemical machining square slotted torsional spring was proposed,analyzing its combined kinematics,designing a special motion device,and establishing a test system for wire electrochemical machining square slotted torsional spring.The experimental research on the electrochemical machining of the wire hole tube electrode to explore the influence of the feed speed and processing voltage parameters on the hole diameter and hole type was studied,and selecting the processing parameter with a feed speed of 0.6mm/min and a processing voltage of 14V,an array of machining holes with a hole diameter of 0.96mm is provided.The process of applying an insulating coating is used to avoid the corrosion of the non-machined surface of the torsion spring during the wire electrochemical machining process.The influence of the processing voltage on the feed speed is explored.Using optimized process parameters and improved process flow,a square slit torsion spring sample with an average slit width of 1.006mm,a size deviation of±0.05mm,and a good surface quality was processed.