陶瓷-金属FGM的聚磁辅助ECDM机理及电磁热耦合建模仿真研究

With the excellent properties and innovative design concept, ceramic-metal functionally graded material (FGM) has attracted worldwide attention. However, the FGM material has characteristics of metal and ceramic, which makes the proecss of micro-machining complex and changeable. We proposed the novel method of concentrated magnetic assisted electrochemical discharge machining (ECDM) to research the problem of micro-process and electromagnetic thermal coupling in ceramic-metal functionally graded material. The metal phase material was used as ECDM auxiliary anode. The ingenious design idea combines the ECDM technical characteristics with the structural characteristics of FGM, which can provide new thinking ideas to reprocessing ceramic-metal functionally gradient materials. Firstly, we want to do the ECDM experiment, and explore the electrochemical discharge machining mechanism ceramic-metal functionally gradient materials. Secondly, we design the concentrated magnetic structure, research the effect of magnetic assisted ECDM on concentrated magnetic FGM. Electrical, magnetic and thermal single physical field modeling and simulation were researched。Finally, a reasonable electromagnetic thermal coupling mathematical model and multi-physics field coupled simulation were research. Creating a new concentrated magnetic assisted ECDM theory can provide a theoretical guidance for electromagnetic thermal coupling problem in other research domain. Exploring the mechanism of electrochemical discharge machining ceramic-metal FGM can not only enriches the connotation of electrochemical discharge but also provides a new reprocess method. The research results will both have an important theoretical value and have a broad application prospect.

陶瓷-金属功能梯度材料以其优异的特性和新颖的设计理念而备受瞩目。材料兼具金属和陶瓷双重特性，导致微观加工过程复杂多变。提出采用聚磁辅助电化学放电加工方法进行陶瓷-金属材料加工的微观过程和电磁热耦合问题研究。将材料的金属相作为ECDM辅助阳极的设计理念既结合了ECDM的技术特点又巧妙融合了材料的特性，为功能梯度材料的再加工提供新思路。首先，进行试验研究，探索陶瓷-金属功能梯度材料的电化学放电加工机理；其次，设计聚磁磁路，研究聚磁辅助ECDM对加工的影响规律，进行单物理场建模仿真研究；最后，建立合理的电磁热耦合数学模型，完成多场耦合仿真研究，创建全新的聚磁辅助电化学放电加工理论，为其他电磁热耦合问题研究提供理论指导。探索陶瓷-金属功能梯度材料的电化学放电加工机理不但可以丰富电化学放电加工的内涵，而且为先进功能梯度材料的再加工提供一种新方法，研究成果具有重要的理论价值和广阔的应用前景。

SiC/Al陶瓷-金属功能梯度材料具有金属和陶瓷双重特性，在航空航天等领域具有广泛的应用前景。针对SiC/Al陶瓷-金属功能梯度材料的难加工问题，本项研究开展了理论研究和工艺试验研究。主要研究工作包括：1）完成了层厚5mm，成份为5%SiC/Al，10% SiC/Al，15%SiC/Al的功能梯度材料的制备；2）提出一种聚磁辅助电化学放电加工的方法，设计出聚磁磁路，应用该方法获得了高表面质量的加工；3）采用正交与灰关联分析相结合的多目标参数优化，完成了电化学放电加工工作液成份优化研究，获得了高效高质量的工作液配方5%NaCl+16% NaNO3+4%NaClO3；4）建立电化学放电间隙流场仿真 数学模型，完成了SiC/Al功能梯度材料电化学放电间隙流场仿真研究，探索了加工方式对间隙流场的影响机理，并进行了冲液压力、加工深度对加工的影响研究；5）开展了SiC/Al功能梯度材料电化学放电加工单脉冲和连续脉冲温度场仿真研究，并进行了理论与试验数据的对比分析，获得了多目标回归分析经验公式。6）开展了SiC/Al功能梯度材料电化学放电铣削加工研究。探索陶瓷-金属功能梯度材料的电化学放电加工机理不但可以丰富电化学放电加工的内涵，而且为先进功能梯度材料的再加工提供一种新方法，研究成果具有重要的理论价值和广阔的实际应用前景。

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