大长径比异形深孔电熔爆加工工具电极的设计

Design of Electrode for Shaped Deep-Hole Electrofusion Explosion Machining with Large Length-to-Diameter Ratio

针对高硬度材料且具有大长径比异形截面深孔的高效加工难题,提出采用深孔机械加工与电熔爆加工结合的方法,通过加工过程中的难点分析,采用深孔刀具设计方法对工具电极进行结构设计,设计了具有自导向、且能够连续自动冷却内排屑功能的加工工具电极,实现了工件材料硬度为HRC40、长度为8000 mm、长径比为200的某零件异形深孔的加工。结果表明:一次加工后,孔表面粗糙度Ra≤12.5μm,直线度≤3 mm·m^(-1),加工中材料平均去除率可达0.6 g·s^(-1),实现了异形截面孔的高效加工。

A method of combining deep-hole mechanical processing with electrofusion explosion processing is propose to achieve high-efficiency machining of high-hardness materials and shaped deep holes with large length-to-diameter cross-sections in mechanical processing.Through the analysis of the difficulties in the process,using the deep hole tool design method to design the tool electrode structure,developed a self-guided,continuous and automatic cooling internal chip removal function of the machining tool electrode,realized the workpiece material hardware degree HRC40,length 8000 mm,length to diameter ratio of 200 for the processing of special-shaped deep holes of a part.The results show that after one-time processing,the hole surface roughness Ra≤12.5μm,straightness≤3 mm·m-1,and the average removal rate of materials during processing can reach 0.6 g·s-1,which realizes the efficient processing of special-shaped cross-section holes.