基于电化学圆周3D打印的切割片制备基础研究

Fundamental research on preparation of cutting blades based on electrochemical circumferential 3Dprinting

[目的]制备超薄金刚石切割片的常规侧面沉积工艺存在两侧不一致而引起切割受力不对称、导致加工缺陷等问题。为此,提出了一种基于电化学圆周3D打印的新技术,探索圆环超薄片沿圆周生长的可能性,从基础上先研究以圆周径向逐圈生长的方式制备环形镍薄片的方法。[方法]在自主设计制造的电化学圆周3D打印实验平台上,探索在旋转状态下环形镍薄片的成形机制。先建立等比二维仿真模型,采用COMSOL Multiphysics有限元仿真软件进行仿真,研究不同电沉积参数对沉积层轮廓及电解质电流密度分布的影响。然后通过单因素实验,研究了加工电流和阴极旋转速率对镍薄片沉积形貌及其均匀性的影响。[结果]在45钢基体直径50mm、极间距1.5mm的情况下,当加工电流为0.10~0.15A,阴极旋转速率为1.0~1.5 r/s时,可以获得均匀性较好的镍金属薄片。[结论]本研究为以电化学圆周3D打印方式制备精密切割片打下了基础。

[Introduction]The conventional side deposition process for manufacturing ultrathin diamond cutting blades often results in inconsistency between the two sides,leading to asymmetric cutting forces and processing defects.A novel technology based on electrochemical circumferential 3D printing was proposed to explore the possibility of circumferentially growing annular ultrathin blades.[Method]The mechanism of forming annular nickel sheets in a rotating state was explored by using a home-made electrochemical circumferential 3D printing experimental platform.Initially,a proportional two-dimensional simulation model was established,and COMSOL Multiphysics finite element simulation software was employed to simulate the effects of different electrodeposition parameters on the contour of the deposition layer and the distribution of electrolyte current density.Subsequently,single-factor experiments were conducted to study the effects of processing current and cathode rotation speed on the morphology and uniformity of nickel sheets.[Result]Nickel sheets with good uniformity were obtained by electrodeposition on 45 steel substrates with a diameter of 50 mm at a current of 0.10 to 0.15 A,an inter-electrode distance of 1.5 mm,and a cathode rotation speed of 1.0-1.5 r/s.[Conclusion]This research lays the foundation for using electrochemical circumferential 3D printing to prepare precision cutting blades.