【摘要】：混氣電解加工是一種在常規(guī)電解液中混入一定量有壓力的氣體進(jìn)行電解加工的加工方法。相比于常規(guī)電解加工技術(shù),混氣電解加工可以提高材料的集中蝕除能力、減小毛坯的遺傳誤差、提高零件的復(fù)制精度。半個(gè)世紀(jì)以來的大量研究工作使混氣電解加工技術(shù)在鍛模型腔和葉片型面的加工中得以成功應(yīng)用。然而,混氣電解加工的機(jī)理和間隙內(nèi)流場分布特性等問題還需進(jìn)一步明確,并且高速攝像等新技術(shù)的發(fā)展也為深入研究該問題提供了更為便捷的條件。本文采用鈦合金TC4材料開展了混氣電解加工技術(shù)研究,主要研究內(nèi)容包括:(1)搭建了含氣率可調(diào)的氣液混合系統(tǒng)。為了使氣體和電解液在加工區(qū)形成穩(wěn)定的氣液兩相流,設(shè)計(jì)了一套基于文丘里效應(yīng)的氣液混合單元,保證了經(jīng)由該系統(tǒng)得到的氣液兩相混合物的均勻程度滿足鈦合金TC4混氣電解加工試驗(yàn)要求。(2)分析了混氣電解加工間隙內(nèi)氣液兩相流場的分布特性。為了研究混氣電解加工的流場特點(diǎn),模擬實(shí)際電解加工環(huán)境設(shè)計(jì)了加工間隙變化的矩形流道,對(duì)間隙內(nèi)的氣液兩相流動(dòng)進(jìn)行高速攝像觀測,初步總結(jié)了氣液兩相流隨間隙變化的分布特性以及電解液中混入氣體對(duì)間隙內(nèi)流場、電導(dǎo)率分布的影響等工藝規(guī)律。(3)分析了鈦合金TC4材料的混氣電化學(xué)溶解特性。通過比較分析鈦合金TC4材料在靜液、常規(guī)電解加工條件以及混氣電解加工條件等多種環(huán)境下的極化曲線和E-t曲線,給出了電解液的流動(dòng)和氣體的混入對(duì)鈦合金TC4材料電解加工的影響,總結(jié)了鈦合金TC4在混氣電解液中的電解加工特性。(4)開展了鈦合金TC4毛坯的混氣電解加工基礎(chǔ)試驗(yàn)研究。以臺(tái)階型的鈦合金TC4毛坯為研究對(duì)象,進(jìn)行多種含氣率參數(shù)的混氣電解加工試驗(yàn)研究,考察含氣率的變化對(duì)鈦合金TC4毛坯的整平性能、加工表面質(zhì)量和雜散腐蝕程度等的影響,結(jié)果表明含氣率β=0.55左右是混氣電解加工鈦合金TC4工件較好的參數(shù)。(5)開展了鈦合金TC4葉片混氣電解加工應(yīng)用研究。以扭曲型面的航空發(fā)動(dòng)機(jī)葉片為對(duì)象進(jìn)行優(yōu)選參數(shù)的混氣電解加工試驗(yàn),并與常規(guī)電解加工對(duì)比,試驗(yàn)結(jié)果表明混氣電解加工在加工毛坯余量差較大、型面扭曲的零件時(shí)具有更好的整平能力與復(fù)制精度,加工進(jìn)入平衡狀態(tài)更快,加工結(jié)束后的型面余量差顯著減小,葉片型面精度更高,但表面粗糙度稍有增大。
[Abstract]:Mixed Gas Electrochemical Machining (ECM) is a kind of machining method in which a certain amount of gas with pressure is mixed into conventional electrolyte for ECM. Compared with the conventional ECM technology, mixed gas ECM can improve the concentrated erosion ability of materials, reduce the genetic error of blank, and improve the reproduction accuracy of parts. A great deal of research work in the past half century has made the mixed gas electrolytic machining (ECM) successfully applied in the machining of forging die cavity and blade surface. However, the mechanism of mixed gas ECM and the characteristics of flow field distribution in the gap need to be further clarified, and the development of new technologies such as high-speed video camera also provides a more convenient condition for further study of this problem. The main contents of this paper are as follows: (1) A gas-liquid mixing system with adjustable gas content is set up. In order to form a stable gas-liquid two-phase flow between gas and electrolyte in the processing zone, a gas-liquid mixing unit based on Venturi effect was designed. The uniformity of the gas-liquid two-phase mixture obtained by this system is ensured to meet the requirements of the TC4 mixed gas electrolysis machining test of titanium alloy. (2) the gas-liquid two-phase flow field distribution in the gap of the mixed gas ECM is analyzed. In order to study the flow field characteristics of mixed gas ECM, a rectangular channel with varying gap was designed to simulate the actual ECM environment. The gas-liquid two-phase flow in the gap was observed by high speed camera. The distribution characteristics of gas-liquid two-phase flow along with the gap and the influence of the mixed gas in the electrolyte on the flow field and conductivity distribution in the gap were summarized. (3) the electrochemical dissolution characteristics of titanium alloy TC4 materials were analyzed. The polarization curves and E-t curves of titanium alloy TC4 materials under hydrostatic, conventional ECM and mixed gas ECM conditions were compared and analyzed. The effects of electrolyte flow and gas mixing on the electrochemical machining of titanium alloy TC4 materials are presented, and the electrochemical machining characteristics of titanium alloy TC4 in the mixture electrolyte are summarized. (4) the basic experiments of mixed gas electrochemical machining of titanium alloy TC4 blank are carried out. Taking the step type titanium alloy TC4 blank as the research object, the experiments of mixed gas electrolysis machining with various gas content parameters were carried out, and the effects of the change of the gas content on the leveling performance, machining surface quality and stray corrosion degree of the titanium alloy TC4 blank were investigated. The results show that the gas content 尾 = 0.55 is a good parameter for TC4 workpiece of titanium alloy. (5) the application of mixed gas ECM for titanium alloy TC4 blade is studied. The mixed gas ECM experiment with the aero-engine blade with twisted surface as the object is carried out, and compared with conventional ECM, the test results show that the ECM with mixed gas has a large margin in machining blank. When the shape face is twisted, it has better leveling ability and copying precision, and the machining enters into the balance state more quickly, the residual difference of the shape surface after machining is obviously reduced, the precision of the blade surface is higher, but the surface roughness is slightly increased.
【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)】：TG662

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