Simulation and Prediction of Small Holes Machined by RCUECM

旋轉超聲電解複合加工小孔的模擬與預測

劉澤祥(Ze-Xiang Liu) ； 李曙生(Shu-Sheng Li) ； 張斌(Bin Zhang)

《中國機械工程學刊》 40卷4期 (2019/08) Pp. 355-363

摘要

One of the ways to improve technological factors in electrochemical machining is by introduction of the ultrasonic vibration of cathode. In order to study the forming law and the course of hole machined by the rotary combined ultrasonic and electrochemical machining (RCUECM), the small holes were processed by the RCUECM with hollow cathode with different machining time, then three-dimensional simulation machining are carried out based on ANSYS CFX using the hollow cathode. Simulation outcomes and experimental outcomes were carried out using the same machining time, the entrance diameter; bottom diameter and machining depth were measured and analyzed afterwards. The comparison results show that as the vibration of the cathode is applied in the simulation, the flow field is similar to the actual one in experiments, when the voltage was applied in the simulation, the couple filed of electric and flow was formed, so based on what was mentioned above, the simulation machining is suitable for describing the course of holes machined by RCUECM in actual. The three-dimensional profiles of holes were obtained by the three-dimensional simulation and were similar to these holes in experiments. Therefore the simulation can be used to predict the profile of parts machined by RCUECM, and it is a reliable method to describe the machining course in RCUECM for the three-dimensional simulation machining, which is helpful for the studying the forming law of the RCUECM.

關鍵字

Rotary combined electrochemical machining (RCUECM) ； small holes ； forming law ； simulation machining

並列摘要

陰極施加超聲振動是提高電解加工技術參數的方法之一。為研究旋轉超聲複合加工小孔成型規律和加工過程，採用空心管電極進行了不同加工時間的小孔旋轉超聲電解複合加工試驗，並基於ANSYS CFX軟體，採用空心管電極，對不同加工時間的小孔分別進行了三維模擬加工。對比兩種方法加工的小孔，測量並分析入口直徑、出口直徑和加工深度。分析結果表明由於在模擬中考慮了陰極振動，電解液流場與實際加工流場更貼近，而在模擬加工中施加電壓，形成了實際加工中電場和流場的耦合場，基於以上分析，三維模擬加工方法是適合描述小孔旋轉超聲電解複合加工過程的，且三維模擬加工中顯示的小孔的三維輪廓與實際加工的小孔輪廓相似，因此該方法可以用來預測旋轉超聲電解複合加工的零件輪廓，是一種描述旋轉超聲電解複合加工過程的可靠方法，這有助於旋轉超聲電解複合加工成型規律的研究。