Research on ultrasonically assisted electrochemical machining process
Research on ultrasonically assisted electrochemical machining process
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DOI：
10.1007/s00170-010-2774-4
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发表时间：
2011-02-01
影响因子：
3.4
通讯作者：
Skoczypiec, Sebastian
中科院分区：
文献类型：
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作者：
Skoczypiec, Sebastian
电解加工是加工难加工材料和加工自由曲面的一项重要技术。在电解加工中，材料是通过电化学溶解过程去除的，因此加工零件时不会产生残余应力，也不会造成刀具磨损。为了改善电解加工中的工艺因素，引入电极工具超声振动是合理的。这种方法称为超声辅助电化学加工(USAECM)。本文第一部分对USAECM过程中电解液在间隙中的流动进行了分析。基于计算流体力学方法，分析了电解液在阳极和阴极之间的多相、湍流和非定常流动(假设存在空化现象)。对所得解的讨论是确定USAECM过程中电解液流动最佳条件的基础。论文的第二部分是关于USAECM工艺的实验研究。在机械加工情况下获得的结果的经典实验验证是非常困难的，但超声振动的影响可以通过工艺因素的变化来间接观察(与没有超声强化的加工相比)，而数值模拟的结果则为理解工艺因素变化的原因和方向提供了可能。研究证明，超声振动改变了电化学溶解的条件，最佳的振动幅度使降低电极极化成为可能。
Electrochemical machining (ECM) is an important technology in machining difficult-to-cut materials and to shape free-form surfaces. In ECM, material is removed by electrochemical dissolution process, so part is machined without inducing residual stress and without tool wear. To improve technological factors in electrochemical machining, introduction of electrode tool ultrasonic vibration is justifiable. This method is called as ultrasonically assisted electrochemical machining (USAECM). In the first part of the paper, the analysis of electrolyte flow through the gap during USAECM has been presented. Based on computational fluid dynamic methods, multiphase, turbulent and unsteady electrolyte flow between anode and cathode (under assumption that cavitation phenomenon occurs) has been analysed. Discussion of the obtained solutions is the base to define optimal conditions of electrolyte flow in case of USAECM process. The second part of the paper is connected with experimental investigations of USAECM process. Classic experimental verification of obtained results in case of machining is extremely difficult, but influence of the ultrasonic vibration can be observed indirectly by changes in technological factors (in comparison to machining without ultrasonic intensification), whereas results of numerical simulation give possibility to understand reason and direction of technological factors changes. Investigations proved that ultrasonic vibrations change conditions of electrochemical dissolution and for optimal amplitude of vibration gives possibility to decrease the electrode polarisation.