本文選題：冰層反襯　切入點(diǎn)：電火花-電解復(fù)合加工　出處：《南京航空航天大學(xué)》2017年碩士論文　論文類型：學(xué)位論文

【摘要】：隨著航空工業(yè)的發(fā)展,航空發(fā)動(dòng)機(jī)關(guān)鍵零部件上出現(xiàn)了大量微小孔結(jié)構(gòu),這些孔的孔徑一般在0.3~2mm之間,由于航空發(fā)動(dòng)機(jī)關(guān)鍵零部件的材料一般為高強(qiáng)度、高硬度的難加工材料,如高溫合金、鈦合金、金屬間化合物等,而且這些微小孔還要求加工表面無再鑄層、無微裂紋、無熱影響區(qū)等,所以傳統(tǒng)的加工方法已經(jīng)很難滿足要求。電火花-電解復(fù)合穿孔加工結(jié)合了電火花加工與電解加工各自的優(yōu)勢(shì),既能通過電火花快速蝕除材料保證較高的穿孔效率,又能通過電解溶解作用去除電火花加工產(chǎn)生的再鑄層、熱影響區(qū)等缺陷,有望成為無再鑄層氣膜冷卻孔有效的加工方法。但這種方法在小孔穿透后工作液會(huì)流失,造成加工間隙中缺液,出口處孔壁電解不充分,可能會(huì)有再鑄層殘留。因此需要找到一種反襯材料填充在工件背面,既能在小孔穿透后提供充足穩(wěn)定的反向沖液,又能方便的填充到諸如渦輪葉片這種結(jié)構(gòu)復(fù)雜腔體中,而且要求去除方便、經(jīng)濟(jì)、環(huán)保等。本文提出了冰層反襯層電火花-電解復(fù)合穿孔加工方法。即在工件背面填充冰層,利用液氮制冷,保持加工過程中反襯冰層一直存在,理論上反襯冰層在小孔穿透后可以提供充足穩(wěn)定的反向沖液,同時(shí)管電極中的常溫高壓工作液會(huì)將冰層局部融化,不會(huì)對(duì)管電極繼續(xù)進(jìn)給造成阻礙,可以保證管電極對(duì)孔壁的電解作用持續(xù)穩(wěn)定的進(jìn)行。另一方面,反襯冰層也降低了加工區(qū)域的溫度,尤其降低了工件的溫度。本文搭建了冰層反襯電火花-電解復(fù)合穿孔試驗(yàn)平臺(tái),研究了低溫環(huán)境對(duì)復(fù)合穿孔加工過程中的影響,以及反襯冰層對(duì)小孔復(fù)合加工質(zhì)量的影響。論文主要研究?jī)?nèi)容如下:(1)提出了冰層反襯電火花-電解復(fù)合穿孔加工新方法,并詳細(xì)闡述其加工原理,從理論上分析了反襯冰層對(duì)穿孔加工工作液流場(chǎng)的影響。設(shè)計(jì)并搭建冰層反襯電火花-電解復(fù)合加工試驗(yàn)平臺(tái),通過監(jiān)測(cè)加工過程中工具電極與工件電極之間的電壓、電流波形,驗(yàn)證反襯冰層在小孔穿透后的反向沖液效果。通過觀察加工后反襯冰層的融化情況,研究了不同底部停頓時(shí)間對(duì)冰層融化程度的影響。進(jìn)行工件在常溫和低溫環(huán)境下電火花加工產(chǎn)生再鑄層厚度對(duì)比試驗(yàn),研究工件溫度對(duì)電火花加工產(chǎn)生再鑄層的影響。(2)進(jìn)行工件在常溫與低溫環(huán)境下電火花-電解復(fù)合加工對(duì)比試驗(yàn),借助加工過程中電壓、電流波形以及溫度等參數(shù)的監(jiān)測(cè),分析工件在低溫狀態(tài)下電解加工過程的電壓、電流波形與常溫環(huán)境下的異同點(diǎn)。對(duì)比常溫和低溫兩種加工環(huán)境下復(fù)合加工效率,從加工過程中電解、短路、放電所占的時(shí)間比例以及單個(gè)脈沖蝕除量的角度,分析了工件在低溫狀態(tài)下復(fù)合加工材料去除率略微降低的原因。研究了工件在常溫和低溫環(huán)境下不同工作液濃度對(duì)工具電極損耗的影響,得到了工件在低溫環(huán)境下加工可以減小工具電極相對(duì)損耗的結(jié)論。(3)進(jìn)行冰層反襯電火花-電解復(fù)合穿孔加工試驗(yàn)。研究了工作液濃度、冰層溶液濃度以及底部停頓時(shí)間對(duì)小孔出入口孔徑、孔形、錐度以及孔壁再鑄層去除效果的影響。最后進(jìn)行45°斜小孔復(fù)合加工試驗(yàn),分析了無反襯、石蠟反襯以及冰層反襯三種情況下,斜小孔穿透后工作液流場(chǎng)的不同變化,研究了冰層反襯復(fù)合加工對(duì)斜小孔出入口孔形的影響,并對(duì)斜小孔穿透后孔壁及出入口工件表面進(jìn)行了電場(chǎng)仿真,從電流密度的分布解釋了斜小孔出入口產(chǎn)生倒圓現(xiàn)象的原因。最后研究了底部停頓時(shí)間對(duì)斜小孔孔壁再鑄層去除效果的影響。
[Abstract]:With the development of aviation industry, the emergence of a large number of micro pore structure of key parts of the aeroengine, the aperture hole is generally between 0.3~2mm, as the key parts of the aeroengine materials for high strength, high hardness of hard processing materials, such as high-temperature alloy, titanium alloy, intermetallic compounds, and these tiny holes also required the surface no recast layer, no cracks, no heat affected zone, so the traditional processing method has been difficult to meet the requirements of electrical discharge electrolysis combined perforation process combines the advantages of EDM and ECM respectively, both by electric spark rapid erosion material to ensure high efficiency and perforation. Produce EDM recast layer removal by electrolytic dissolution, defects in the heat affected zone, is expected to become the processing without re cast layer of film cooling holes effectively. But this method in wear Through working fluid will be lost, resulting in lack of liquid in the machining gap, the outlet hole wall of electrolysis is not sufficient, there may be recast layer residues. So we need to find a contrast material filled in the back of the workpiece, which can penetrate the holes in the reverse to provide adequate and stable flushing, and convenient filling such as turbine this leaves the complex structure of the cavity, and easy to remove, economy, environmental protection and so on. This paper proposes the ice layer contrast electrical discharge electrolysis combined perforation processing method. The ice is filled in the back of the workpiece, using liquid nitrogen refrigeration, keep in the process of contrasting ice has always existed, contrast theory can provide adequate and stable ice reverse flushing in keyhole penetration, while tube at room temperature high pressure working fluid in the electrode will not hinder the local ice melt, to continue to feed tube electrode, can ensure continuous electrolysis tube electrode on the hole wall Stable. On the other hand, making ice also reduces the temperature of the cutting area, especially reduce the temperature of the workpiece. This paper built the ice foil electrical discharge electrolysis combined perforation test platform, to study the influence of composite perforation in the process of low temperature environment, and the influence of compound contrast of ice. The machining quality of the hole the main research contents are as follows: (1) proposed ice contrast electrical discharge electrolysis combined perforation method processing, and describes the working principle, and analyzes the influence of perforation fluid ice contrast processing flow. To design and build ice contrast EDM combined electrochemical machining test platform, through the voltage between the tool the monitoring process of the electrode and the workpiece electrode current waveform, verify the contrast effect in reverse flushing ice after penetrating holes. By melting ice processing after contrast observation. Study on the influence of different conditions, the bottom of the ice melting degree of the pause time. The workpiece is recast layer thickness contrast test under normal and low temperature environment of EDM, workpiece temperature recast layer have influence on EDM. (2) of the workpiece at room temperature and low temperature environment for electrical discharge electrolysis composite processing contrast test, with the help of voltage in the process of monitoring parameters of current waveform and the temperature of the workpiece in the machining process analysis of voltage in the low temperature and normal temperature environment, current waveform similarities and differences. Compared to normal temperature and low temperature environment of two kinds of processing compound processing efficiency, from the process of electrolysis, short circuit ratio time for a single pulse discharge and the erosion angle, analyzes the causes of the workpiece in the composite materials processing under low temperature removal rate decreased slightly. The workpiece at normal temperature and low temperature ring Effect of different concentration under the environment of tool electrode, the workpiece in a low temperature environment can reduce the tool electrode relative wear conclusions. (3) of the ice foil electrical discharge electrolysis combined machining experiment concentration, solution concentration and the ice at the bottom of the hole entrance aperture pause time the hole shape, taper, and hole wall recast layer influence the removal efficiency. Finally, 45 degree oblique hole machining test, analysis of the contrast, contrast and contrast of three kinds of paraffin ice under the condition of different changes in the inclined hole after penetrating fluid flow field, on the contrast effect of ice composite processing entrance hole on the inclined hole, and the inclined hole after penetrating the hole wall and entrance surface electric field simulation, from the distribution of the current density explains why the inclined hole round phenomenon. In the end of the entrance The effect of the bottom pause time on the removal efficiency of the recasting layer of the slanted hole wall.

【學(xué)位授予單位】：南京航空航天大學(xué)
【學(xué)位級(jí)別】：碩士
【學(xué)位授予年份】：2017
【分類號(hào)】：TG66

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