脉冲气体辅助掩模电解加工技术

doi:10.7527/S1000-6893.2021.25646

Abstract

Abstract: Surface texture are widely used in key components of aero engines to help improve their heat dissipation and lubrication. Through-mask electrochemical machining is a highly efficient method for processing surface texture, despite some problems in processing such as uneven flow velocity of electrolyte, difficult to discharge the processed products and ensure the consistency of the surface texture, etc. Therefore, a new method of pulsed gas-assisted through-mask electrochemical machining was proposed, which could use the instantaneous impact force of the pulse gas to wash the electrolysis products in the machining area, thereby promoting the renewal of the electrolyte. In order to study the process law of pulsed gas-assisted through-mask electrochemical machining, under the fixed condition of a single nozzle, a multi-physics model of gas-liquid two-phase flow coupled with electric field was established based on COMSOL Multiphysics simulation software. Through theoretical analysis and experimental study, it was proved that this method has a strong disturbance effect on the fluid in the processing area. The simulation results show that the maximum fluid flow velocity at the bottom of the mask hole was about 3.5 mm/s at a jet velocity of 100 m/s. Traces of product dis-charge can be clearly observed on the surface of the processed mask. In addition, the effects of different process parameters on processing consistency and efficiency were studied. The experimental results show that with the increase of the pulse interval of the jet and the decrease of the gas injection speed, the processing consistency would increase and the processing efficiency would be less. In the experiment, the standard deviation of micro-pit depth could reach a mini-mum of 0.75 μm and the average depth could reach a maximum of 15.2 μm. Finally, the machining results with or without pulsed gas assist and the forming laws of simulation and experiment with pulsed gas assist were compared. Then, the array pits with the standard deviation of depth and the average depth of 1.06 μm and 10.7 μm were processed in the condition of nozzle scanning. Combining theoretical analysis and experimental research results, it was proved that this method had a strong disturbing effect on the fluid in the processing area, and could improve processing efficiency and consistency.

Key words: pulsed gas, through-mask electrochemical machining, surface texture, gas-liquid two-phase flow, multi-physics coupling

CLC Number:

V261.94

MA Shihe, LI Zhichao, LIU Guixian, ZHANG Yongjun, WANG Ruixiang. Pulse gas-assisted through-mask electrochemical machining technology[J]. ACTA AERONAUTICAET ASTRONAUTICA SINICA, 2022, 43(4): 525646.

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Pulse gas-assisted through-mask electrochemical machining technology

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