为加工难加工构型大长宽比薄壁 T 形槽,文中提出了使用中空锯齿状阴极进行内喷式供液的方式进行电解加工的方法,通过对各种不同入口条件、不同喷口形状等条件下的流道模型进行了仿真,基于COMSOL软件仿真计算后得到了在不同入口条件时,间隙内电解液流速分布和加工工件表面形貌的变化规律.研究结果表明:入口条件为 0.2MPa 及以上时,间隙内各点电解液流速的均值大于 5 m·s-1,可以有效减少钝化现象的产生;选用圆形喷口时能够得到高流速、高稳定性、周期性脉动的流场,加工表面流速最高点和最低点的电解液速度分别为 0～13 m·s-1 和 0～8 m·s-1 流速差小,加工表面尺寸误差得到有效改善,加工表面斜率大幅减小,整体加工速度将得到有效提高;并使用上述参数范围进行 T 型槽电解加工实验验证,得到符合加工要求的大长宽比T型槽结构,结论可为大长宽比薄壁 T 形槽电解加工提供工艺技术参考.
Modeling and Simulation Analysis of Electrolytic Milling Flow Field for T Groove with Large Aspect Ratio
In order to process components having a thin-walled T-slot with a large aspect ratio,the paper presents a method of electrolytic machining using a hollow sawtooth cathode for internal injection liquid supply.The flow channel model was simulated under the conditions of different inlets and different nozzle shapes.Based on the simulation with COMSOL software,the distribution of electrolyte flow rate in the gap and the variation of workpiece surface morphology under different inlet conditions were found.The results show that when the inlet condition is 0.2 MPa or above,the average electrolyte flow rate at each point in the gap is greater than 5m/s,effectively reducing the passivation phenomenon.When the circular nozzle is selected,the flow field with high flow rate,high stability and periodic fluctuation can be obtained.The highest and lowest electrolyte flow rate of the machined surface is 0～13 m·s-1 and 0～8 m·s-1,respectively,a small difference.The dimensional error and the slope of the machined surface are effectively reduced,and the overall processing speed will be effectively increased.The above parameters are used in the electrolytic machining of a T-groove,obtaining the T-groove with a large length-width ratio that meets the machining requirements.This conclusion can provide technical reference for electrochemical machining of thin-wall T-slots with high aspect ratios.
electrochemical machininglarge aspect ratiot-shaped grooveflow field simulation
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