Influence of electrolyte flow mode on characteristics of electrochemical machining with electrolyte suction tool
Influence of electrolyte flow mode on characteristics of electrochemical machining with electrolyte suction tool
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DOI：
10.1016/j.ijmachtools.2019.04.010
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发表时间：
2019-07-01
影响因子：
14
通讯作者：
Natsu, Wataru
中科院分区：
文献类型：
--
作者：
Liu, Guixian;Zhang, Yongjun;Natsu, Wataru
电解加工（ECM）是一种很有前途的非传统形状生成加工方法，具有加工难加工金属材料无残余应力、表面质量好、效率高、无刀具磨损等优点，但在很多情况下，加工精度相对较差以及可能存在的环境风险等问题阻碍了该工艺的进一步应用。因此，已经提出了一种电解质抽吸工具用于电解加工，期望通过限制抽吸工具内的电解质流动来给出这些问题的解决方案。本文从理论和实验两方面研究了吸气工具中不同的电解液流动方式对电解加工过程特性的影响。建立了气吸式电解加工过程中湍流两相流场与电场耦合的多物理模型。设计并进行了一系列的观察实验和加工实验，以阐明电解液流场的特点，并验证模拟结果。结果表明，内流模式下，大量的空气被吸入加工区域，形成相对稳定的气液两相区，导致加工特性较差。同时，电解液被限制在一个小的区域下的外向流动模式（OFM），这有效地提高了电解加工过程的表面质量和加工精度。
Electrochemical machining (ECM) is a promising nontraditional machining method for shape generation, which has many advantages such as capable of processing difficult-to-cut metallic materials without residual stress, good surface quality, high efficiency, no tool wear, etc. However, in many cases, problems of relatively poor machining accuracy and possible environmental risks hinder further application of this process. Hence an electrolyte suction tool has been proposed for ECM, which is expected to give a solution to these problems by restraining the electrolyte flow within the suction tool. In this paper, the effects of different electrolyte flow modes in suction tool on characteristics of ECM process were investigated both theoretically and experimentally. A mull-physics model coupling with a turbulent two-phase flow field and an electrical field was established for the ECM with the suction tool. A set of observational experiments and machining experiments were designed and conducted to clarify the characteristics of the electrolyte flow field and verify the results of simulation. The results show that under the inward flow mode (IFM), much surrounding air is sucked into the machining area and a relatively stable gas-liquid zone is formed, leading to poor machining characteristics. Meanwhile, the electrolyte is confined to a small area under the outward flow mode (OFM), which effectively improves both surface quality and machining accuracy of the ECM process.