TC4钛合金射流电解质等离子体微加工流场仿真与实验研究

doi:10.3969/j.issn.1004-132X.2026.09.023

摘要/Abstract

摘要：

提出了一种射流电解质等离子体微加工（Jet-EPM）方法。以TC4钛合金为研究对象，开展了定点射流加工实验，探究加工时间对加工形貌演化的影响机制。通过移动射流微加工实验，分析了喷嘴移动速度及扫描重叠率对加工形貌的影响规律。结果表明：定点射流加工初期，材料去除集中于射流接触中心区域；随着加工时间的延长，加工定域性逐渐降低。微槽加工中，加工质量随喷嘴移动速度提高而提升，但速度过高会导致路径两端材料过度去除。扫描加工时，若路径重叠率低于75%，工件表面将出现垂直于扫描方向的波纹状起伏。

关键词: 电解质等离子体, 射流加工, TC4钛合金, 表面形貌, 流场

Abstract:

A jet electrolyte plasma micro-machining（Jet-EPM） method was proposed. Using TC4 titanium alloy as the research subject， stationary jet machining experiments were first conducted to investigate the influence mechanism of machining time on the evolution of the machined morphology. Subsequently， moving jet micro-machining experiments were performed to analyze the influence of nozzle traverse speed and scan overlap ratio on the machined morphology. The results indicate that during the initial stage of stationary jet machining， material removal is concentrated in the central contact area of the jet. As machining time increases， the localization of material removal gradually decreases. In micro-groove machining， the machining quality improves with increasing nozzle traverse speed， but excessively high speeds cause excessive material removal at both ends of the path. During scanning machining， if the path overlap ratio is below 75%， wavy undulations perpendicular to the scanning direction appear on the workpiece surface.

Key words: electrolyte plasma, jet machining, TC4 titanium alloy, surface morphology, flow field

中图分类号:

TG580

易军, 陈洪峰, 苗长春, 尹泽清, 邓辉. TC4钛合金射流电解质等离子体微加工流场仿真与实验研究[J]. 中国机械工程, 2026, 37(9): 2305-2313.

YI Jun, CHEN Hongfeng, MIAO Changchun, YIN Zeqing, DENG Hui. Flow Field Simulation and Experimental Study of Jet Electrolyte Plasma Micro-machining on TC4 Titanium Alloy[J]. China Mechanical Engineering, 2026, 37(9): 2305-2313.

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链接本文: https://www.cmemo.org.cn/CN/10.3969/j.issn.1004-132X.2026.09.023

https://www.cmemo.org.cn/CN/Y2026/V37/I9/2305

图/表 16

图1 加工原理图

Fig.1 Processing schematic

图2 实验平台

Fig.2 Experimental setup

表1 定点加工实验参数

Tab. 1 Experimental parameters for stationary jet machining

实验参数	数值
抛光液	1%（质量分数，下同）氟化钠+3%盐酸羟胺
抛光电压/V	300
温度/℃	85
时间t/s	15、30、45、60、90
喷嘴直径/mm	0.6
射流间隙/mm	8

表2 移动加工实验参数

Tab. 2 Experimental parameters for moving jet machining

实验参数	数值
抛光液	1%氟化钠+3%盐酸羟胺
抛光电压/V	300
温度/℃	85
时间t/s	30
喷嘴直径/mm	0.6
射流间隙/mm	8
移动速度v/（mm·s $- 1$ ）	10、20、30、40
重叠率/%	25、50、62.5

表2 移动加工实验参数

Tab. 2 Experimental parameters for moving jet machining

实验参数	数值
抛光液	1%氟化钠+3%盐酸羟胺
抛光电压/V	300
温度/℃	85
时间t/s	30
喷嘴直径/mm	0.6
射流间隙/mm	8
移动速度v/（mm·s $- 1$ ）	10、20、30、40
重叠率/%	25、50、62.5

图3 平均过切量计算示意图

Fig.3 Schematic diagram of the calculation of the average overcut

图4 仿真模型示意图

Fig.4 Schematic diagram of the simulation model

图5 不同加工时间下的凹坑形貌与电流密度分布

Fig.5 Pit morphology and current density distribution at different processing time

图6 不同加工时间下的凹坑实物图

Fig.6 Physical images of pits under different processing time

图7 不同加工时间下的凹坑二维形貌图

Fig.7 Two-dimensional topography of pits under different processing time

图8 不同加工时间下的凹坑截面轮廓

Fig.8 Cross-sectional profiles of pits at different processing time

图9 不同加工时间下的平均过切量

Fig.9 Average overcut at different processing time

图10 不同喷嘴移动速度下的微槽实物图

Fig.10 Physical images of micro-grooves under different nozzle travel speeds

图11 槽宽沿扫描方向的分布

Fig.11 Distribution of groove width along the scanning direction

图12 槽底中部沿扫描方向的截面轮廓曲线

Fig.12 Cross-sectional profile at the middle of groove bottom along the scanning direction

图13 不同重叠率下的微槽横截面流速及压力分布

Fig.13 Flow velocity and pressure distribution on micro-groove cross-section at different overlap rates

图14 不同扫描重叠率下的微槽三维形貌与截面轮廓图

Fig.14 Three-dimensional morphology and cross-sectional profile of the micro-groove under different scanning overlap rates

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