复杂型腔电解加工成形规律分析及试验研究

Research on Forming Rule of Electrochemical Machining of Complex Cavity by Analysis and Experiments

电解加工适用于包含复杂型腔的难加工材料整体构件的高效加工,但复杂型腔电解加工时加工余量的分布需进一步深入研究。针对阴极曲面上各点法向与进给方向夹角不同时工件成形过程存在差异的问题,对阴极建立特定夹角处加工间隙的微分方程,模拟不同法向与进给方向夹角,并采用规则形状阴极开展直流电解加工和脉冲振动耦合电解加工工艺对比试验,以优选合适的微分方程模拟复杂型腔在上述加工模式下的成形过程。研究成果已应用于闭式整体叶盘叶间流道的电解加工。

Electrochemical machining(ECM)is suitable for machining parts with complex cavities and made by material that hard to cut.However,allowance distribution of complex cavities during ECM still needs to be researched further.To solve the problems that angles between normal direction and feeding direction are different at points on cathode surface,making forming process changed,differential equations of machining gap at points with specific angles were constructed to simulate different angles between normal direction and feeding direction.Cathodes with regular shapes were used to carry out contrastive experiments of direct current ECM and pulse-vibration ECM to choose suitable differential equations to simulate forming process of complex cavity under the above machining modes.Achievement of research has been used in efficient machining of integral shrouded blisk channels.