深窄槽结构的脉动场耦合电解铣削加工新方法研究

深窄槽结构在航空发动机及燃气轮机等产品核心零部件上发挥重要作用，其精密、高效加工难题是制约相关产品发展的一个技术瓶颈，亟需突破。为此本项目创新电极结构和流场-电场耦合模式，提出脉动场耦合电解铣削新方法，利用端面异形、侧壁周向非连续绝缘的新型管电极驱动电解铣削过程中流场轴向脉动和电场周向脉动，从而强化冲液效果、离散材料溶解过程和产物分布，调控两者耦合过程，大幅提高电解产物排出效率，降低其对加工过程的影响，实现深窄槽结构的精密、高效电解铣削成型。项目拟重点探究电解液脉动流动特性及产物输运强化机制、脉动场耦合作用下材料电化学溶解行为、深窄槽成型规律等关键科学问题；突破端面异形、侧壁周向非连续绝缘管电极结构设计与制备、电解液同轴回流、脉动场耦合电解铣削参数匹配等关键技术，充分释放电解铣削潜能，解决深窄槽加工难题。本项目的开展将对提升难加工材料深窄槽结构精密制造水平具有重要的科学意义和应用价值。

Deep-narrow groove plays an important role in the core parts of aero-engine and gas turbine. The high precision and efficiency machining process is an urgent bottleneck that restricts the development of related products. This project introduced a novel structure of tube tool electrode as well as the coupling mode between flow field and electric field, and proposed a method, named electrochemical milling with pulsating multi-physics fields coupling for manufacturing deep-narrow groove. In this new method, a novel tube tool electrode with shaped end face and circumferential non-continuous insulation layer on the sidewall was introduced to drive axial pulsating flow field and circumferential pulsating electric field, which could enhance the flushing process as well as the discrete material dissolving process and by-product distribution. By regulating the coupling process of pulsating fields, the removal rate of by-product could be improved sharply, and its influence on the machining process is reduced, which is helpful for the manufacture of deep-narrow groove with high quality and efficiency. This project will thoroughly explore the pulsating flowing characteristics of electrolyte and strengthening mechanism for the by-product transport, the electrochemical dissolution behavior of materials under the action of pulsating fields coupling, and the shaping law of deep-narrow groove. Meanwhile, this project will focus on the key techniques such as the design and preparation of the novel tube electrode, electrolyte coaxial reflux technology, and process parameters matching during electrochemical milling. It will release the potential of electrochemical milling fully to solve the problem of manufacturing deep-narrow groove. The implementation of this project will have important theoretical and practical significance for improving the precision manufacturing of the deep-narrow groove on hard to machine materials.