Effect of electrode materials on the surface quality of aero-engine honeycomb ring with short arc grinding
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摘要: 短电弧（SEAM）磨削航空发动机蜂窝环是一种新型的航空航天盘环类零件的加工方法，针对此类零件低刚度、薄壁的特点，采用短电弧低电压放电磨削，达到高精度、高效率和高质量的加工要求。由于采用不同材料的电极会产生不同的加工效果，为了研究其性能规律，采用铸铁、紫铜、黄铜及石墨4种材料进行短电弧磨削航空发动机蜂窝环试验，分析其重铸层厚度、表面粗糙度（Ra）、表面微观形貌（SEM）、加工表面元素、加工电流波形、电极损耗率（TWR）。结果表明铸铁材料电极放电磨削后的重铸层厚度最低，并且表面无微裂纹，而石墨电极加工后的重铸层厚度最大，且石墨电极TWR最高，影响加工精度，故不适用此类零件短电弧磨削加工，紫铜电极加工时的放电稳定，且电解电流最大，若延长空转时间则能有效地产生电解反应去蚀除重铸层。Abstract: SEAM grinding of aero-engine honeycomb ring is a new machining method for aerospace disk ring parts. In view of the characteristics of low stiffness and thin wall of such parts, Seam grinding is adopted to achieve high precision, high efficiency and high quality machining requirements. Because the electrode with different materials will produce different machining effects, in order to study its performance, the short arc grinding test of aero-engine honeycomb ring was carried out by using cast iron, copper, brass and graphite. The thickness of recast layer, surface roughness (Ra), surface morphology (SEM), machining surface elements, machining current waveform and electrode loss ratio (TWR) were analyzed. The results show that the recast layer thickness of cast iron electrode after discharge grinding is the lowest, and there is no micro-crack on the surface, while the recast layer thickness of graphite electrode is the largest, and the TWR of graphite electrode is the highest, which affects the machining accuracy, so it is not suitable for short arc grinding of such parts. The discharge is stable and the electrolytic current is the largest during the processing of copper electrode.If the idling time is prolonged, electrolytic reaction can be effectively generated to remove the recast layer.
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Key words:
- short arc grinding /
- honeycomb ring /
- recast layer /
- roughness
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