基于油包水纳米乳液的无重铸层电火花电解复合成形加工方法基础研究

本项目聚焦于难切削材料及复杂形状零件高精度、高表面质量成形加工难题，提出基于油包水纳米乳液的无重铸层电火花电解复合成形加工方法。本方法以油包水纳米乳液作为电火花成形和电解加工的双特性工作液，将两种电加工形式有机结合，通过改变油包水纳米乳液水相电解质浓度和电加工参数取值等，引起工作液击穿状态的变化，从而实现电火花成形与电解加工的可控调节。当电火花成形与电解加工的强度达到合适比例时，可实现高精度、无重铸层的成形加工。研究油包水纳米乳液中电化学溶解材料去除和液滴运动的微观物理过程，建立阳极材料电化学溶解模型，揭示电化学溶解材料去除机理；研究多场耦合下的复合成形加工特性，揭示电加工形式的转变规律，阐明电火花电解可控调节机制；研究复合成形加工的间隙流场特性，建立相应数学模型，优化设计间隙流场；研究复合成形加工工艺，揭示其工艺规律；本项目研究有助于提升难切削材料及复杂形状零件成形加工的技术和理论水平。

This project focuses on the sinking machining challenges of high accuracy and high surface quality for difficult-to-cut materials and complex-shaped parts. A method of electrical discharge and electrochemical hybrid sinking machining without recast layer based on water-in-oil nanoemulsion is presented in this project. Water-in-oil nanoemulsion is used as the bi-characteristic working fluid to combine sinking electrical discharge machining (EDM) and electrochemical machining (ECM) in the method. The electrolyte concentration of water-in-oil nanoemulsion and the values of machining parameters are varied to change the breakdown state of the working fluid, so as to realize the controllable adjustment of sinking EDM and ECM. The workpiece with high accuracy and high-quality surface can be obtained when the strength of sinking EDM and ECM reaches an appropriate ratio. The micro-physical processes of material removal by ECM and the movements of nanodroplets are investigated. Electrochemical dissolution model of the anode material is established. The material removal mechanism of ECM is revealed. The characteristics of hybrid sinking machining under multi-field coupling are studied. The transformation law and the controllable adjustment mechanism of sinking EDM and ECM are revealed. The characteristic of the flow field in machining gap of hybrid sinking machining is researched. The corresponding mathematical model is established, and the flow field is optimized. The technological law of hybrid sinking machining is studied and revealed. The research of this project is helpful to improve the technical and theoretical level of sinking machining of difficult-to-cut materials and complex-shaped parts.