旋转超声电解复合加工小孔流场仿真

摘要/Abstract

摘要：

为解决电解加工深小孔中电解液难以进入加工区和电解产物难以排出的问题，构建了内喷式旋转超声电解复合加工装置，进行了电解加工、旋转电解加工和旋转超声电解复合加工小孔的对比试验。试验结果表明，阴极旋转能明显提高孔的圆度，旋转超声电解复合加工具有最大的平均加工电流，所加工孔的直径、深度都为三者中最大，表明其材料去除率是最大的。在此基础上，利用有限元ANSYS CFX软件,建立了气液两相流三维气穴模型，分析了阴极旋转和阴极高频振动对电解加工流场、电场的影响。仿真结果表明：阴极旋转使得气泡在阴极表面聚集，不利于气泡的排出，阴极振动加速了电解液的运动，有利于气泡的排出，因此具有最大的材料去除率。

关键词: 旋转超声电解复合加工；小孔；有限元仿真, 流场

Abstract:

In order to solve the difficulties to update the electrolyte and discharge the products in the electrochemical machining(ECM) for deep-small holes, the internal rotary ultrasonic electrolytic composite machining device was constructed,and the comparative experiments of ECM,rotary electrochemical machining(RECM) and RUECM were carried out.The results show that the roundness of holes is improved by the rotation of cathode and the average current is the largest in the RUECM,thus the diameter and the depth of the holes machined by RUECM are the largest, which indicates that the material removal rate (MRR) is the greatest, too. Based on those, the effects of the rotation and vibration of cathode on the flow field and electric field were analyzed by ANSYS CFX with the three-dimensional two-phase flow cavitation model. The simulation results show that when cathode rotates,the air bubbles are gathered on the cathode surfaced,which is not conducive to the discharge of air bubbles; when cathode vibrates,the motion of electrolyte is accelerated,which is conducive to the discharge of air bubbles, therefore,it has the greatest MRR in RUECM,which provides a basis for future researches.

Key words: rotary combined ultrasonic and electrochemical machining（RUECM）;small holes;finite element simulation, flow field

中图分类号:

TG662

刘泽祥, 康敏, 李曙生. 旋转超声电解复合加工小孔流场仿真[J]. 中国机械工程, 2016, 27(06): 748-753.

Liu Zexiang, Kang Min, Li Shusheng. Flour Field Simulation of Small Holes Machined by the RUECM[J]. China Mechanical Engineering, 2016, 27(06): 748-753.

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