多物理场耦合分析下的电解加工环形窄槽数值模拟研究

穆瑞元; 曹岩; 黄亮; 贾峰

doi:10.13433/j.cnki.1003-8728.20190325

多物理场耦合分析下的电解加工环形窄槽数值模拟研究

doi: 10.13433/j.cnki.1003-8728.20190325

西安工业大学机电工程学院, 西安 710021

基金项目:

陕西省重点研发计划项目 2018ZDXM-GY-077

陕西省教育厅重点实验室科研计划项目 18JS043

西安工业大学校长基金项目 XAGDXJJ17004

详细信息

作者简介:
穆瑞元(1995-), 硕士研究生, 研究方向为特种加工, 17795837325@163.com

通讯作者:
曹岩, 教授, 博士生导师, 博士后, caoyan@xatu.edu.cn

中图分类号: TQ151
计量
- 文章访问数: 183
- HTML全文浏览量: 141
- PDF下载量: 22
- 被引次数: 0
出版历程
- 收稿日期: 2019-08-08
- 刊出日期: 2020-11-01

Numerically Simulating Electrolytic Machining of Annular Narrow Slot with Multi-physical Field Coupling Analyzed

School of Mechatronic Engineering, Xi'an Technological University, Xi'an 710021, China

摘要

摘要: 针对环形窄槽结构电解加工过程工艺试验周期长，型面难以预测的问题，建立掩膜电解加工过程电场、流场、温度场耦合数学模型，利用COMSOL软件对多物理场进行数值模拟仿真，得到加工间隙内电解液电流密度、流速和压力的分布规律，并将加工过程中不同时刻耦合场仿真结果进行对比，得到加工进程中各参数变化规律。研究结果表明，多物理场耦合仿真能够准确模拟实际电解加工过程，实现了工艺参数选取，为实际工艺提供了理论依据，对提高窄槽结构电解加工质量和效率有重要意义。
- 环形窄槽 /
- 掩膜电解加工 /
- 多物理场耦合 /
- 数值模拟
Abstract: To solve the problem of long test period and difficult prediction of shape and surface in the process of electrochemical machining of annular narrow slot structure, a coupled mathematical model of electric field, flow field and temperature field was established. The multi-physical field coupling simulation was conducted with the COMSOL software to obtain the distribution patterns of the density, velocity and pressure of electrolytic current in the machining gap. The simulation results on the coupling field in different periods in the machining process were compared to obtain the variation patterns of each parameter. The multi-physical field coupling simulation can accurately simulate the actual electrolytic machining process, select process parameters, provide a theoretical basis for actual processes and significantly improve the quality and efficiency of the electrolytic machining of a narrow slot.
- annular narrow slot /
- electrolytic machining /
- multi-physical field coupling /
- simulation

HTML全文

图 1 环形窄槽掩膜电解加工原理图

下载: 全尺寸图片幻灯片

图 2 掩模电解定域性分析图

下载: 全尺寸图片幻灯片

图 3 环形窄槽几何模型

下载: 全尺寸图片幻灯片

图 4 环槽加工区域模型

下载: 全尺寸图片幻灯片

图 5 各物理场之间关系图

下载: 全尺寸图片幻灯片

图 6 不同进口压力下极间流速

下载: 全尺寸图片幻灯片

图 7 极间流速与电解液温度变化趋势

下载: 全尺寸图片幻灯片

图 8 不同加工间隙对应的电流密度云图

下载: 全尺寸图片幻灯片

图 9 槽深变化关系图

下载: 全尺寸图片幻灯片

图 10 不同加工时刻仿真对比

下载: 全尺寸图片幻灯片

表 1 数值模拟参数

参数	数值
阳极材料体积化学当量/(mm³·(A·min)^-1)	1.832 06
电解液密度/(kg·m^-3)	1 100
初始电导率/(S·m^-1)	6.79
初始加工温度/K	293.15
动力粘度/(Pa·s)	0.97×10^-3
传热系数/(W·(m²·K)^-1)	15 000
常压热容/(J·(kg·K)^-1)	4 150
热导率/(W·(m·K)^-1)	0.65
入口压力/MPa	0.2
出口压力/MPa	0.08
电压/V	10

下载: 导出CSV

参考文献(16)

[1]	吴蒙华, 关浩.硬质合金导线轮环槽静液脉冲电解加工[J].现代制造工程, 2002, (2):28-29 http://www.cnki.com.cn/Article/CJFDTotal-XXGY200202012.htm Wu M H, Guan H. Cutting tiny annular groove on hard alloy guide wheel by method of electrochemical machining with pulse current in static electrolyte[J]. Modern Manufacturing Engineering, 2002, (2):28-29(in Chinese) http://www.cnki.com.cn/Article/CJFDTotal-XXGY200202012.htm
[2]	朱晓龙.电解窄槽类工件的加工规律研究[D].杭州: 浙江理工大学, 2013 Zhu X L. The processing research on metal narrow groove craft of electrochemical[D]. Hangzhou: Zhejiang Sci-Tech University, 2013(in Chinese)
[3]	吴林烽, 李湘生, 王龙.一种医用针管窄槽电解加工工艺研究[J].机械工程师, 2013, (10):5-7 http://www.cnki.com.cn/Article/CJFDTotal-JXGU201310019.htm Wu L F, Li X S, Wang L. Electrolysis process of narrow groove on a medical needle[J]. Mechanical Engineer, 2013, (10):5-7(in Chinese) http://www.cnki.com.cn/Article/CJFDTotal-JXGU201310019.htm
[4]	王亚南.微细环槽电解线切割加工系统及试验研究[D].广州: 广东工业大学, 2016 Wang Y N. System design and experimental research on wire electrochemical micro-machining of ring groove[D]. Guangzhou: Guangdong University of Technology, 2016(in Chinese)
[5]	贠康, 张长富, 艾海红, 等.304不锈钢微型环槽的微细电解铣削加工技术研究[J].内燃机与配件, 2018, (3):108-109 http://www.cnki.com.cn/Article/CJFDTOTAL-NRPJ201803050.htm Yun K, Zhang C F, Ai H H, et al. Research on micro electrochemical milling for 304 stainless steel micro ring groove[J]. Internal Combustion Engine & Parts, 2018, (3):108-109(in Chinese) http://www.cnki.com.cn/Article/CJFDTOTAL-NRPJ201803050.htm
[6]	吕焱明, 赵建社, 范延涛, 等.大长宽比深窄槽电解加工阴极结构设计[J].航空制造技术, 2018, 61(3):46-53 http://www.cnki.com.cn/Article/CJFDTotal-HKGJ201803011.htm Lü Y M, Zhao J S, Fan Y T, et al. Cathode structure design of electrochemical machining for deep narrow grooves with high length-width ratio[J]. Aeronautical Manufacturing Technology, 2018, 61(3):46-53(in Chinese) http://www.cnki.com.cn/Article/CJFDTotal-HKGJ201803011.htm
[7]	Qu N S, Chen X L, Li H S, et al. Fabrication of PDMS micro through-holes for electrochemical micromachining[J]. The International Journal of Advanced Manufacturing Technology, 2014, 72(1):487-494
[8]	宋曼.活动模板电解加工微小凹坑阵列研究[D].南京: 南京航空航天大学, 2010 Song M. Research on machining micro-pits array by ECM with active masks[D]. Nanjing: Nanjing University of Aeronautics and Astronautics, 2010(in Chinese)
[9]	蔡伟伟.基于干膜掩模的电解加工微小凹坑阵列试验研究[D].南京: 南京航空航天大学, 2015 Cai W W. Research on electrochemical micromachining of micro-dimple arrays with a dry-film photoresist mask[D]. Nanjing: Nanjing University of Aeronautics and Astronautics, 2015(in Chinese)
[10]	Wang F, Zhao J S, Lv Y M, et al. Experimental research on improving accuracy of electrochemical machining of deep narrow grooves[J]. The International Journal of Advanced Manufacturing Technology, 2018, 96(9-12):3217-3225 doi: 10.1007/s00170-018-1700-z
[11]	陈少国, 于兆勤, 刘江文, 等.掩膜电解加工小孔仿真分析及实验研究[J].机械设计与制造, 2018, (8):155-158 http://www.cnki.com.cn/Article/CJFDTotal-JSYZ201808046.htm Chen S G, Yu Z Q, Liu J W, et al. Simulation analysis and experimental research on micro-pits of mask electrochemical machining[J]. Machinery Design & Manufacture, 2018, (8):155-158(in Chinese) http://www.cnki.com.cn/Article/CJFDTotal-JSYZ201808046.htm
[12]	李晓龙, 刘书海, 肖华平.涡轮钻具叶片电解加工过程多场耦合仿真分析[J].石油矿场机械, 2019, 48(3):1-6 http://www.cnki.com.cn/Article/CJFDTotal-SKJX201903001.htm Li X L, Liu S H, Xiao H P. Multiphysics simulation of electrochemical machining process for turbodrill blade[J]. Oil Field Equipment, 2019, 48(3):1-6(in Chinese) http://www.cnki.com.cn/Article/CJFDTotal-SKJX201903001.htm
[13]	王阳, 傅秀清, 王清清, 等.微坑阵列掩膜电解加工试验研究[J].机械科学与技术, 2018, 37(6):896-902 doi: 10.13433/j.cnki.1003-8728.2018.0612 Wang Y, Fu X Q, Wang Q Q, et al. Experimental study on electrochemical machining of micro pits array mask[J]. Mechanical Science and Technology for Aerospace Engineering, 2018, 37(6):896-902(in Chinese) doi: 10.13433/j.cnki.1003-8728.2018.0612
[14]	周小超, 曹昌勇.基于COMSOL电解加工温度场仿真[J].齐齐哈尔大学学报, 2018, 34(4):41-44 http://www.cnki.com.cn/Article/CJFDTotal-QQHE201804010.htm Zhou X C, Cao C Y. Simulation of ECM temperature field based on COMSOL[J]. Journal of Qiqihar University, 2018, 34(4):41-44(in Chinese) http://www.cnki.com.cn/Article/CJFDTotal-QQHE201804010.htm
[15]	刘国强, 柳禄, 何成奎, 等.电解加工过程多物理场耦合仿真及试验研究[J].机械设计, 2018, 35(12):29-35 http://www.cnki.com.cn/Article/CJFDTotal-JXSJ201812006.htm Liu G Q, Liu L, He C K, et al. Multi-physics field coupling simulation and experimental study of ECM process[J]. Journal of Machine Design, 2018, 35(12):29-35(in Chinese) http://www.cnki.com.cn/Article/CJFDTotal-JXSJ201812006.htm
[16]	Wang D Y, Zhu Z W, Wang N F, et al. Investigation of the electrochemical dissolution behavior of Inconel 718 and 304 stainless steel at low current density in NaNO₃ solution[J]. Electrochimica Acta, 2015, 156:301-307 doi: 10.1016/j.electacta.2014.12.155