冲液方式对短电弧-电化学复合加工性能的影响研究

Effect of flushing mode on the performance of short electric arc and electrochemical compound machining

  • 摘要: 针对短电弧-电化学复合加工时内-外冲液方式存在的加工不稳定及加工效率低等问题,提出了一种更适用于短电弧-电化学复合加工的外气-内液冲液方式。在加工过程中通过侧面冲入高压空气,实现加工间隙内短电弧加工与电化学加工相结合的同时,改善了间隙流场分布,提高了短电弧-电化学复合加工效率及工件表面质量。基于Fluent软件进行内-外冲液及外气-内液冲液方式的流场仿真,分析了侧面高压气体的冲入对间隙流场分布状态及介质电导率的影响。通过对比实验研究了两种冲液形式下的材料去除率、单位能耗体积比以及表面热损伤层。结果表明,外气-内液冲液方式下的材料去除率(MRR)可以达到750 mm3/min,相对于内-外冲液方式提高了1.9倍,单位能耗体积比仅有149.98 kJ/cm3,加工后工件表面无重铸层,尺寸精度也得到了较大改善,实现了材料的无重铸层加工。

     

    Abstract: In order to solve the problems of unstable machining and low machining efficiency in the internal-external flushing mode of short electric arc and electrochemical compound machining, this paper proposes an external air-internal liquid flushing mode that is more suitable for short electric arc and electrochemical compound machining. In the machining process, high pressure air is injected into the side to realize the combination of short arc machining and electrochemical machining in the machining gap, improve the gap flow field distribution, and improve the efficiency of short electric arc and electrochemical compound machining and workpiece surface quality.Based on Fluent software, the flow field simulations of internal-external flushing and external air-internal liquid flushing were carried out to analyze the effect of flushing of side high-pressure gas on the flow field distribution of the gap and the electrical conductivity of the medium. The material removal rate, unit energy consumption volume ratio and surface thermal damage layer under the two flushing forms were investigated by comparative experiments. The results show that the material removal rate (MRR) of the external air-internal liquid flushing mode can reach 750 mm3/min, which is 1.9 times higher than that of the internal-external flushing mode, and the unit energy consumption volume ratio is only 149.98 kJ/cm3, and the surface of the workpiece is free of recast layer after machining, and the dimensional accuracy is also greatly improved, realizing the machining of material without recast layer.

     

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