CN106238838A - Method for electrochemically machining ellipsoidal bamboo joint hole - Google Patents
Method for electrochemically machining ellipsoidal bamboo joint hole Download PDFInfo
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- CN106238838A CN106238838A CN201610616100.6A CN201610616100A CN106238838A CN 106238838 A CN106238838 A CN 106238838A CN 201610616100 A CN201610616100 A CN 201610616100A CN 106238838 A CN106238838 A CN 106238838A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23H—WORKING OF METAL BY THE ACTION OF A HIGH CONCENTRATION OF ELECTRIC CURRENT ON A WORKPIECE USING AN ELECTRODE WHICH TAKES THE PLACE OF A TOOL; SUCH WORKING COMBINED WITH OTHER FORMS OF WORKING OF METAL
- B23H3/00—Electrochemical machining, i.e. removing metal by passing current between an electrode and a workpiece in the presence of an electrolyte
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23H—WORKING OF METAL BY THE ACTION OF A HIGH CONCENTRATION OF ELECTRIC CURRENT ON A WORKPIECE USING AN ELECTRODE WHICH TAKES THE PLACE OF A TOOL; SUCH WORKING COMBINED WITH OTHER FORMS OF WORKING OF METAL
- B23H3/00—Electrochemical machining, i.e. removing metal by passing current between an electrode and a workpiece in the presence of an electrolyte
- B23H3/04—Electrodes specially adapted therefor or their manufacture
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23H—WORKING OF METAL BY THE ACTION OF A HIGH CONCENTRATION OF ELECTRIC CURRENT ON A WORKPIECE USING AN ELECTRODE WHICH TAKES THE PLACE OF A TOOL; SUCH WORKING COMBINED WITH OTHER FORMS OF WORKING OF METAL
- B23H3/00—Electrochemical machining, i.e. removing metal by passing current between an electrode and a workpiece in the presence of an electrolyte
- B23H3/08—Working media
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Abstract
一种电化学加工椭球形竹节孔的方法,包括以下步骤:1)工具电极A的制备;2)工具电极B的制备;3)圆形竹节孔的加工;先将工具电极A进给到待加工工件上预先加工好的光孔中,接着将电解液沿着工具电极A与待加工工件上的光孔内壁之间的缝隙自下而上流动,待加工工件表面在电场作用下被去除,形成圆形竹节孔;4)椭球形竹节孔的加工:将步骤3)中的工具电极A取出,在圆形竹节孔内插入工具电极B,通过机床主轴带动工具电极B按设定角度沿着圆周方向往复摆动,圆形竹节孔处于电解加工区的内壁面得到二次电解加工,圆形竹节孔逐渐形成椭球形竹节孔。本发明可加工孔径尺寸小、加工工件表面性能不会受到切削力的影响。
A method for electrochemically machining an ellipsoidal bamboo hole comprises the following steps: 1) preparing a tool electrode A; 2) preparing a tool electrode B; 3) machining a circular bamboo hole; firstly feeding the tool electrode A into a pre-machined light hole on a workpiece to be machined, and then flowing the electrolyte from bottom to top along the gap between the tool electrode A and the inner wall of the light hole on the workpiece to be machined, and the surface of the workpiece to be machined is removed under the action of the electric field to form a circular bamboo hole; 4) machining an ellipsoidal bamboo hole: taking out the tool electrode A in step 3), inserting the tool electrode B into the circular bamboo hole, and driving the tool electrode B to swing back and forth along the circumferential direction at a set angle through the machine tool spindle, and the inner wall surface of the circular bamboo hole in the electrolytic machining area is subjected to secondary electrolytic machining, and the circular bamboo hole gradually forms an ellipsoidal bamboo hole. The present invention can machine a small aperture size, and the surface performance of the machined workpiece will not be affected by the cutting force.
Description
技术领域technical field
本发明涉及电化学加工领域,尤其是一种电化学加工椭球形竹节孔的方法。The invention relates to the field of electrochemical machining, in particular to a method for electrochemically machining ellipsoidal bamboo joint holes.
背景技术Background technique
随着社会的进步与科技的发展,在现代航空航天、汽车、机床等制造行业中,对于使用过程中受力受热比较严重的零件,为了减轻由于冷却不彻底带来的零件变形,延长其使用寿命,越来越多的采用非圆异形截面,即横截面不是圆形,而是椭圆、变椭圆、摆线等非圆形状。如现代活塞制造业中普遍采用的异形销孔设计,可以避免在很高的燃烧压力下产生的弹性变形,减轻销孔内侧应力集中的问题,使得活塞获得更好的性能。此外,在航空发动机滚子轴承中采用非圆滚道,可以有效解决高速轻载时滚子的打滑现象,避免对发动机造成破坏性的影响。而这些非圆异形截面零件因为其复杂的形状,加工精度,对制造加工技术提出了很高的要求。With the progress of society and the development of science and technology, in modern aerospace, automobile, machine tool and other manufacturing industries, for parts that are subjected to severe stress and heat during use, in order to reduce the deformation of parts caused by incomplete cooling and prolong their use More and more non-circular special-shaped cross-sections are used, that is, the cross-section is not circular, but non-circular shapes such as ellipse, variable ellipse, and cycloid. For example, the special-shaped pin hole design commonly used in the modern piston manufacturing industry can avoid elastic deformation under high combustion pressure, alleviate the problem of stress concentration inside the pin hole, and enable the piston to obtain better performance. In addition, the use of non-circular raceways in aero-engine roller bearings can effectively solve the phenomenon of roller slippage at high speed and light load, and avoid destructive effects on the engine. These non-circular special-shaped cross-section parts have high requirements on manufacturing and processing technology because of their complex shape and processing accuracy.
目前,非圆异形截面零件的加工方法大多是通过主轴的回转运动与切削刀具的径向伸缩运动的合成来实现的。但在实际加工方面则存在种种问题,主要是因为在回转镗杆上安装高频响微量进给机构和控制驱动装置存在着安装空间小,实施控制和测量难度高等问题。At present, the machining methods of non-circular special-shaped cross-section parts are mostly realized through the synthesis of the rotary motion of the spindle and the radial telescopic motion of the cutting tool. However, there are various problems in actual processing, mainly because there are problems such as small installation space and high difficulty in implementing control and measurement when installing high-frequency micro-feeding mechanism and control drive device on the rotary boring bar.
发明内容Contents of the invention
为了克服现有技术存在的不足,本发明提供了一种电化学加工椭球形竹节孔的方法,其是利用通电状态下金属材料发生电化学溶解的原理进行,利用专门设计的工具电极,控制加工时间、加工电压、工具电极的摆动实现小孔径表面椭球形微结构的加工。In order to overcome the deficiencies in the prior art, the present invention provides a method for electrochemically machining ellipsoidal bamboo-shaped holes, which uses the principle of electrochemical dissolution of metal materials in the state of electricity, and uses specially designed tool electrodes to control Processing time, processing voltage, and the swing of the tool electrode realize the processing of the ellipsoidal microstructure on the small-aperture surface.
本发明解决其技术问题所采用的技术方案是:The technical solution adopted by the present invention to solve its technical problems is:
一种电化学加工椭球形竹节孔的方法,所述方法包括以下步骤:A method for electrochemically machining ellipsoidal bamboo joint holes, said method comprising the following steps:
1)工具电极A的制备:1) Preparation of tool electrode A:
将一光滑圆柱形金属丝或金属管的表面沿圆周方向按等间隔制成环形凹槽,然后在环形凹槽内涂覆绝缘材料并进行固化,形成金属导电部与绝缘部相互间隔的竹节形工具电极A;The surface of a smooth cylindrical metal wire or metal tube is made into annular grooves at equal intervals along the circumferential direction, and then insulating material is coated and cured in the annular grooves to form a bamboo joint with metal conductive parts and insulating parts spaced apart from each other Shaped tool electrode A;
2)工具电极B的制备:2) Preparation of tool electrode B:
将一光滑圆柱形金属丝或金属管的表面沿轴向前后两侧制成相互平行的平面,在轴向左右两侧分别按等间隔制成弧形凹槽,然后在弧形凹槽以及前后两侧平行的平面上涂覆绝缘材料并进行固化,形成前后两侧绝缘、左右两侧的金属导电部与绝缘部相互间隔的工具电极B;其中,工具电极B上的相邻两个弧形凹槽之间的间隔与工具电极A上的相邻两个环形凹槽之间的间距相同,工具电极A上的环形凹槽的上下宽度与工具电极B上的弧形凹槽的上下宽度相同,工具电极B的金属导电部的横截面的半径与工具电极A的金属导电部的横截面的半径相同;The surface of a smooth cylindrical metal wire or metal tube is made into planes parallel to each other along the front and rear sides of the axial direction, and arc-shaped grooves are made at equal intervals on the left and right sides of the axial direction, and then the arc-shaped grooves and the front and rear Insulating material is coated on two parallel planes and cured to form a tool electrode B in which the front and rear sides are insulated, and the metal conductive parts on the left and right sides are spaced from the insulating part; wherein, two adjacent arcs on the tool electrode B The interval between the grooves is the same as the distance between two adjacent annular grooves on the tool electrode A, and the upper and lower widths of the annular grooves on the tool electrode A are the same as the upper and lower widths of the arc-shaped grooves on the tool electrode B , the radius of the cross-section of the metal conducting part of the tool electrode B is the same as the radius of the cross-section of the metal conducting part of the tool electrode A;
3)圆形竹节孔的加工:3) Processing of circular slub holes:
先将工具电极A进给到待加工工件上预先加工好的光孔中,接着将电解液沿着工具电极A与待加工工件上的光孔内壁之间的缝隙自下而上流动,然后将待加工工件接电源正极,工具电极A接电源负极,处于电解液包围的待加工工件与工具电极A的金属导电部之间形成电解加工区,待加工工件表面在电场作用下被去除,形成圆形竹节孔;First feed the tool electrode A into the pre-processed light hole on the workpiece to be processed, and then flow the electrolyte from bottom to top along the gap between the tool electrode A and the inner wall of the light hole on the workpiece to be processed, and then The workpiece to be processed is connected to the positive pole of the power supply, and the tool electrode A is connected to the negative pole of the power supply. An electrolytic machining zone is formed between the workpiece to be processed surrounded by the electrolyte and the metal conductive part of the tool electrode A. The surface of the workpiece to be processed is removed under the action of an electric field to form a circle. shaped bamboo hole;
4)椭球形竹节孔的加工:4) Processing of ellipsoidal bamboo joint holes:
将步骤3)中的工具电极A取出,在圆形竹节孔内插入工具电极B,且工具电极B的金属导电部、绝缘部与工具电极A的金属导电部、绝缘部在轴向方向相对应,同时,工具电极B的前后两侧的绝缘层前后布置;设定电解液的加工电压和通电时间,通过机床主轴带动工具电极B按设定角度沿着圆周方向往复摆动,圆形竹节孔处于电解加工区的内壁面得到二次电解加工,圆形竹节孔逐渐形成椭球形竹节孔,当达到设定的通电时间后,圆形竹节孔完全形成椭球形竹节孔;Take out the tool electrode A in step 3), insert the tool electrode B into the circular slub hole, and the metal conductive part and the insulating part of the tool electrode B are aligned with the metal conductive part and the insulating part of the tool electrode A in the axial direction. Correspondingly, at the same time, the insulating layers on the front and rear sides of the tool electrode B are arranged front and back; the machining voltage and energization time of the electrolyte are set, and the tool electrode B is driven to reciprocate along the circumferential direction by the machine tool spindle at a set angle, and the circular bamboo joint The inner wall surface of the hole in the electrolytic processing area is subjected to secondary electrolytic processing, and the circular slub hole gradually forms an ellipsoidal slub hole. When the set electrification time is reached, the circular slub hole completely forms an ellipsoidal slub hole;
其中,工具电极B的前后往复摆动的设定角度为30°~60°。Wherein, the setting angle of the reciprocating swing of the tool electrode B is 30°-60°.
进一步,所述步骤1)工具电极A的制备中;Further, in the step 1) preparation of the tool electrode A;
将一光滑圆柱形金属丝或金属管的表面沿圆周方向按等间隔涂覆一层绝缘胶,并在紫外光照射下进行固化,然后将其浸入质量浓度为10%NaNO3的电解液中进行电解腐蚀,将涂覆绝缘胶的圆柱形金属丝或金属管接电源正极,质量浓度为10%NaNO3电解液中的铁片接电源负极,电解腐蚀达到设定时间后,取出圆柱形金属丝或金属管,从而使得圆柱形金属丝或金属管表面裸露部分的金属材料得到腐蚀呈环形凹槽状,然后将之前涂覆的一层绝缘胶去除形成工具电极A的金属导电部,最后在被腐蚀的环形凹槽内均匀涂覆含15%SiC的光敏树脂并在紫外光照射下进行固化,环形凹槽内的光敏树脂层形成工具电极A的绝缘部,从而制得工具电极A。The surface of a smooth cylindrical metal wire or metal tube is coated with a layer of insulating glue at equal intervals along the circumferential direction, and cured under ultraviolet light, and then immersed in an electrolyte solution with a mass concentration of 10% NaNO 3 Electrolytic corrosion, connect the cylindrical metal wire or metal pipe coated with insulating glue to the positive pole of the power supply, and the iron sheet in the electrolyte solution with a mass concentration of 10% NaNO 3 to the negative pole of the power supply. After the electrolytic corrosion reaches the set time, take out the cylindrical metal wire or a metal tube, so that the metal material on the exposed part of the cylindrical wire or metal tube surface is corroded into an annular groove shape, and then the previously coated layer of insulating glue is removed to form the metal conductive part of the tool electrode A. A photosensitive resin containing 15% SiC was evenly coated in the corroded annular groove and cured under ultraviolet light irradiation, and the photosensitive resin layer in the annular groove formed the insulating part of the tool electrode A, thereby producing the tool electrode A.
进一步,所述步骤2)工具电极B的制备中;Further, the step 2) is in the preparation of the tool electrode B;
将一光滑圆柱形金属丝或金属管的表面沿轴向左右两侧绷直涂覆一层绝缘胶并在紫外光照射下进行固化,然后将其侵入到配好的质量浓度为10%NaNO3的电解液中,将涂覆绝缘胶的圆柱形金属丝或金属管接电源正极,质量浓度为10%NaNO3电解液中的铁片接电源负极,电解腐蚀到设定时间后,取出圆柱形金属丝或金属管,从而使得圆柱形金属丝或金属管表面裸露部分的金属材料得到腐蚀,其轴向前后两侧形成相互平行的平面,并在平面上涂覆15%SiC的光敏树脂,并在紫外光照射下进行固化,得到轴向前后两侧绝缘的金属丝或金属管;Stretch the surface of a smooth cylindrical metal wire or metal tube along the left and right sides of the axis, coat a layer of insulating glue and cure it under ultraviolet light, and then infiltrate it into a prepared mass concentration of 10% NaNO 3 In the electrolyte, connect the cylindrical metal wire or metal tube coated with insulating glue to the positive pole of the power supply, and connect the iron sheet in the electrolyte with a mass concentration of 10 % NaNO3 to the negative pole of the power supply. After the electrolytic corrosion reaches the set time, take out the cylindrical Metal wire or metal tube, so that the metal material of the exposed part of the surface of the cylindrical metal wire or metal tube is corroded, and the front and rear sides of the axial direction form parallel planes, and 15% SiC photosensitive resin is coated on the plane, and Curing under ultraviolet light to obtain metal wires or metal tubes insulated on the front and rear sides of the axial direction;
然后,在前后两侧绝缘的金属丝或金属管的轴向左右两侧分别按等间隔涂覆一层绝缘胶,并在紫外光照射下进行固化,固化后将其浸入到质量浓度为10%NaNO3电解液中进行电解腐蚀,将前后两侧绝缘的圆柱形金属丝或金属管接电源正极,质量浓度为10%NaNO3电解液中的铁片接电源负极,电解腐蚀达到设定时间后,取出金属丝或金属管,从而使得金属丝或金属管表面裸露部分的金属材料得到腐蚀呈弧形凹槽状,然后将之前涂覆的一层绝缘胶去除形成工具电极B的金属导电部,最后在被腐蚀的弧形凹槽内均匀涂覆含15%SiC的光敏树脂并在紫外光照射下进行固化,弧形凹槽内的光敏树脂层形成工具电极B的绝缘部,从而制得工具电极B。Then, coat a layer of insulating glue on the left and right sides of the axially left and right sides of the insulated metal wire or metal tube at equal intervals, and cure it under ultraviolet light. After curing, immerse it in a concentration of 10% Electrolytic corrosion is carried out in the NaNO3 electrolyte, and the cylindrical metal wire or metal tube insulated on the front and rear sides is connected to the positive pole of the power supply. The iron sheet in the NaNO3 electrolyte with a mass concentration of 10 % is connected to the negative pole of the power supply. After the electrolytic corrosion reaches the set time , take out the metal wire or metal tube, so that the metal material on the exposed part of the metal wire or metal tube surface is corroded into an arc-shaped groove, and then remove the previously coated layer of insulating glue to form the metal conductive part of the tool electrode B, Finally, a photosensitive resin containing 15% SiC is evenly coated in the corroded arc-shaped groove and cured under ultraviolet light. The photosensitive resin layer in the arc-shaped groove forms the insulating part of the tool electrode B, thereby making the tool Electrode B.
本发明的主要有益效果在于:可实现圆周方向非圆截面冷却孔加工;加工工艺操作简单;在阵列电极情况下,可一次性进行多孔加工,效率高;加工精度较高,可加工孔径尺寸小、加工工件表面性能不会受到切削力的影响。The main beneficial effects of the present invention are: the processing of non-circular cross-section cooling holes in the circumferential direction can be realized; the processing process is simple; in the case of array electrodes, multi-hole processing can be performed at one time, and the efficiency is high; the processing accuracy is high, and the size of the processable aperture is small , The surface properties of the processed workpiece will not be affected by the cutting force.
附图说明Description of drawings
图1a是表面呈环形凹槽状的金属丝的结构示意图。Fig. 1a is a schematic structural diagram of a metal wire whose surface is in the shape of an annular groove.
图2a是图1a制成工具电极A的结构示意图。Fig. 2a is a schematic structural view of the tool electrode A made in Fig. 1a.
图1b是表面呈环形凹槽状的金属管的结构示意图。Fig. 1b is a schematic structural view of a metal tube with an annular groove on its surface.
图2b是图1b制成工具电极A2的结构示意图。Fig. 2b is a schematic structural diagram of the tool electrode A2 made in Fig. 1b.
图3是轴向前后两侧被腐蚀为平面、轴向左右两侧被腐蚀为弧形凹槽的金属丝的结构示意图。Fig. 3 is a schematic diagram of the structure of a metal wire whose axially front and rear sides are corroded into flat surfaces, and whose axially left and right sides are corroded into arc-shaped grooves.
图4是图3制成的工具电极B的结构示意图。FIG. 4 is a schematic structural view of the tool electrode B made in FIG. 3 .
图5是椭球形竹节孔的电解加工原理图。Fig. 5 is a schematic diagram of the electrolytic machining of ellipsoidal bamboo joint holes.
图6是通过工具电极A加工后的圆形竹节孔的纵剖图。FIG. 6 is a longitudinal sectional view of a circular slub hole processed by a tool electrode A. FIG.
图7是图6的主视图。Fig. 7 is a front view of Fig. 6 .
图8是工具电极B在圆形竹节孔内周期性沿轴向周向摆动的示意图。Fig. 8 is a schematic diagram of the tool electrode B periodically oscillating axially and circumferentially in the circular slub hole.
图9是椭球形竹节孔的纵剖图。Fig. 9 is a longitudinal sectional view of an ellipsoidal bamboo joint hole.
图10是图9的主视图。Fig. 10 is a front view of Fig. 9 .
具体实施方式detailed description
下面结合附图对本发明作进一步描述。The present invention will be further described below in conjunction with the accompanying drawings.
参照图1~图10,一种电化学加工椭球形竹节孔的方法,所述方法包括以下步骤:Referring to Figures 1 to 10, a method for electrochemically machining ellipsoidal bamboo joint holes, the method includes the following steps:
2)工具电极A的制备:2) Preparation of tool electrode A:
将一光滑圆柱形金属丝或金属管的表面沿圆周方向按等间隔制成环形凹槽,然后在环形凹槽内涂覆绝缘材料并进行固化,形成金属导电部与绝缘部相互间隔的竹节形工具电极A;The surface of a smooth cylindrical metal wire or metal tube is made into annular grooves at equal intervals along the circumferential direction, and then insulating material is coated and cured in the annular grooves to form a bamboo joint with metal conductive parts and insulating parts spaced apart from each other Shaped tool electrode A;
3)工具电极B的制备:3) Preparation of tool electrode B:
将一光滑圆柱形金属丝或金属管的表面沿轴向前后两侧制成相互平行的平面,在轴向左右两侧分别按等间隔制成弧形凹槽,然后在弧形凹槽以及前后两侧平行的平面上涂覆绝缘材料并进行固化,形成前后两侧绝缘、左右两侧的金属导电部与绝缘部相互间隔的工具电极B;其中,工具电极B上的相邻两个弧形凹槽之间的间隔与工具电极A上的相邻两个环形凹槽之间的间距相同,工具电极A上的环形凹槽的上下宽度与工具电极B上的弧形凹槽的上下宽度相同,工具电极B的金属导电部的横截面的半径与工具电极A的金属导电部的横截面的半径相同;The surface of a smooth cylindrical metal wire or metal tube is made into planes parallel to each other along the front and rear sides of the axial direction, and arc-shaped grooves are made at equal intervals on the left and right sides of the axial direction, and then the arc-shaped grooves and the front and rear Insulating material is coated on two parallel planes and cured to form a tool electrode B in which the front and rear sides are insulated, and the metal conductive parts on the left and right sides are spaced from the insulating part; wherein, two adjacent arcs on the tool electrode B The interval between the grooves is the same as the distance between two adjacent annular grooves on the tool electrode A, and the upper and lower widths of the annular grooves on the tool electrode A are the same as the upper and lower widths of the arc-shaped grooves on the tool electrode B , the radius of the cross-section of the metal conducting part of the tool electrode B is the same as the radius of the cross-section of the metal conducting part of the tool electrode A;
3)圆形竹节孔的加工:3) Processing of circular slub holes:
先将工具电极A进给到待加工工件6上预先加工好的光孔中,接着将电解液沿着工具电极A与待加工工件6上的光孔内壁之间的缝隙自下而上流动,然后将待加工工件接电源正极,工具电极A接电源负极,处于电解液包围的待加工工件6与工具电极A的金属导电部之间形成电解加工区,待加工工件6表面在电场作用下被去除,形成圆形竹节孔;First feed the tool electrode A into the pre-processed optical hole on the workpiece 6 to be processed, and then flow the electrolyte along the gap between the tool electrode A and the inner wall of the optical hole on the workpiece 6 from bottom to top, Then the workpiece to be processed is connected to the positive pole of the power supply, and the tool electrode A is connected to the negative pole of the power supply. An electrolytic machining zone is formed between the workpiece 6 surrounded by the electrolyte and the metal conductive part of the tool electrode A, and the surface of the workpiece 6 to be processed is under the action of an electric field. Removed to form a circular slub hole;
4)椭球形竹节孔的加工:4) Processing of ellipsoidal bamboo joint holes:
将步骤3)中的工具电极A取出,在圆形竹节孔内插入工具电极B,且工具电极B的金属导电部、绝缘部与工具电极A的金属导电部、绝缘部在轴向方向相对应,同时,工具电极B的前后两侧的绝缘层前后布置;设定电解液的加工电压和通电时间,通过机床主轴带动工具电极B按设定角度沿着圆周方向往复摆动,圆形竹节孔处于电解加工区的内壁面得到二次电解加工,圆形竹节孔逐渐形成椭球形竹节孔,当达到设定的通电时间后,圆形竹节孔完全形成椭球形竹节孔;Take out the tool electrode A in step 3), insert the tool electrode B into the circular slub hole, and the metal conductive part and the insulating part of the tool electrode B are aligned with the metal conductive part and the insulating part of the tool electrode A in the axial direction. Correspondingly, at the same time, the insulating layers on the front and rear sides of the tool electrode B are arranged front and back; the machining voltage and energization time of the electrolyte are set, and the tool electrode B is driven to reciprocate along the circumferential direction by the machine tool spindle at a set angle, and the circular bamboo joint The inner wall surface of the hole in the electrolytic processing area is subjected to secondary electrolytic processing, and the circular slub hole gradually forms an ellipsoidal slub hole. When the set electrification time is reached, the circular slub hole completely forms an ellipsoidal slub hole;
其中,工具电极B的前后往复摆动的设定角度为30°~60°。Wherein, the setting angle of the reciprocating swing of the tool electrode B is 30°-60°.
进一步,所述步骤1)工具电极A的制备中;Further, in the step 1) preparation of the tool electrode A;
将一光滑圆柱形金属丝或金属管的表面沿圆周方向按等间隔涂覆一层绝缘胶,并在紫外光照射下进行固化,然后将其浸入质量浓度为10%NaNO3的电解液中进行电解腐蚀,将涂覆绝缘胶的圆柱形金属丝或金属管接电源正极,质量浓度为10%NaNO3电解液中的铁片接电源负极,电解腐蚀达到设定时间后,取出圆柱形金属丝或金属管,从而使得圆柱形金属丝或金属管表面裸露部分的金属材料得到腐蚀呈环形凹槽状,然后将之前涂覆的一层绝缘胶去除形成工具电极A的金属导电部1,最后在被腐蚀的环形凹槽2内均匀涂覆含15%SiC的光敏树脂并在紫外光照射下进行固化,环形凹槽2内的光敏树脂层3形成工具电极A的绝缘部,从而制得工具电极A。The surface of a smooth cylindrical metal wire or metal tube is coated with a layer of insulating glue at equal intervals along the circumferential direction, and cured under ultraviolet light, and then immersed in an electrolyte solution with a mass concentration of 10% NaNO 3 Electrolytic corrosion, connect the cylindrical metal wire or metal pipe coated with insulating glue to the positive pole of the power supply, and the iron sheet in the electrolyte solution with a mass concentration of 10% NaNO 3 to the negative pole of the power supply. After the electrolytic corrosion reaches the set time, take out the cylindrical metal wire or a metal tube, so that the metal material on the exposed part of the cylindrical wire or metal tube surface is corroded into an annular groove shape, and then the previously coated layer of insulating glue is removed to form the metal conductive part 1 of the tool electrode A, and finally in the The corroded annular groove 2 is evenly coated with a photosensitive resin containing 15% SiC and cured under ultraviolet light irradiation. The photosensitive resin layer 3 in the annular groove 2 forms the insulating part of the tool electrode A, thereby making the tool electrode a.
进一步,所述步骤2)工具电极B的制备中;Further, the step 2) is in the preparation of the tool electrode B;
将一光滑圆柱形金属丝或金属管的表面沿轴向左右两侧绷直涂覆一层绝缘胶并在紫外光照射下进行固化,然后将其侵入到配好的质量浓度为10%NaNO3的电解液中,将涂覆绝缘胶的圆柱形金属丝或金属管接电源正极,质量浓度为10%NaNO3电解液中的铁片接电源负极,电解腐蚀到设定时间后,取出圆柱形金属丝或金属管,从而使得圆柱形金属丝或金属管表面裸露部分的金属材料得到腐蚀,其轴向前后两侧形成相互平行的平面4,并在平面4上涂覆15%SiC的光敏树脂,并在紫外光照射下进行固化,得到轴向前后两侧绝缘的金属丝或金属管;Stretch the surface of a smooth cylindrical metal wire or metal tube along the left and right sides of the axis, coat a layer of insulating glue and cure it under ultraviolet light, and then infiltrate it into a prepared mass concentration of 10% NaNO 3 In the electrolyte, connect the cylindrical metal wire or metal tube coated with insulating glue to the positive pole of the power supply, and connect the iron sheet in the electrolyte with a mass concentration of 10 % NaNO3 to the negative pole of the power supply. After the electrolytic corrosion reaches the set time, take out the cylindrical Metal wire or metal tube, so that the metal material of the exposed part of the surface of the cylindrical metal wire or metal tube is corroded, and the front and rear sides of the axial direction form a plane 4 parallel to each other, and 15% SiC photosensitive resin is coated on the plane 4 , and cured under ultraviolet light to obtain a metal wire or a metal tube insulated on the front and rear sides of the axial direction;
然后,在前后两侧绝缘的金属丝或金属管的轴向左右两侧分别按等间隔涂覆一层绝缘胶,并在紫外光照射下进行固化,固化后将其浸入到质量浓度为10%NaNO3电解液中进行电解腐蚀,将前后两侧绝缘的圆柱形金属丝或金属管接电源正极,质量浓度为10%NaNO3电解液中的铁片接电源负极,电解腐蚀达到设定时间后,取出金属丝或金属管,从而使得金属丝或金属管表面裸露部分的金属材料得到腐蚀呈弧形凹槽状,然后将之前涂覆的一层绝缘胶去除形成工具电极B的金属导电部,最后在被腐蚀的弧形凹槽5内均匀涂覆含15%SiC的光敏树脂并在紫外光照射下进行固化,弧形凹槽5内的光敏树脂层3形成工具电极B的绝缘部,从而制得工具电极B。Then, coat a layer of insulating glue on the left and right sides of the axially left and right sides of the insulated metal wire or metal tube at equal intervals, and cure it under ultraviolet light. After curing, immerse it in a concentration of 10% Electrolytic corrosion is carried out in the NaNO3 electrolyte, and the cylindrical metal wire or metal tube insulated on the front and rear sides is connected to the positive pole of the power supply. The iron sheet in the NaNO3 electrolyte with a mass concentration of 10 % is connected to the negative pole of the power supply. After the electrolytic corrosion reaches the set time , take out the metal wire or metal tube, so that the metal material on the exposed part of the metal wire or metal tube surface is corroded into an arc-shaped groove, and then remove the previously coated layer of insulating glue to form the metal conductive part of the tool electrode B, Finally, a photosensitive resin containing 15% SiC is evenly coated in the corroded arc-shaped groove 5 and cured under ultraviolet light irradiation, and the photosensitive resin layer 3 in the arc-shaped groove 5 forms the insulating part of the tool electrode B, thereby Tool electrode B was prepared.
当然其中表面被腐蚀呈环形凹槽状的金属丝/金属管可以采用其他加工方法获得,如3D打印、车削加工,然后再进一步在环形凹槽处涂覆光敏树脂等绝缘材料以获得工具电极A;轴向前后两侧被腐蚀为平面、轴向左右两侧被腐蚀为弧形凹槽5的金属丝/金属管可以采用其他加工方法获得,如3D打印、车削加工,然后再进一步在轴向前后两侧、弧形凹槽处涂覆光敏树脂等绝缘材料以获得工具电极B。Of course, the metal wire/tube whose surface is corroded into an annular groove can be obtained by other processing methods, such as 3D printing, turning, and then further coated with insulating materials such as photosensitive resin on the annular groove to obtain the tool electrode A The metal wires/tubes that are corroded into planes on the front and rear sides of the axial direction and arc-shaped grooves on the left and right sides of the axial direction can be obtained by other processing methods, such as 3D printing, turning, and then further processed in the axial direction. The front and rear sides and the arc-shaped groove are coated with insulating materials such as photosensitive resin to obtain the tool electrode B.
本发明的电解加工原理为:Electrolytic machining principle of the present invention is:
电解液沿着工具电极A与待加工工件6光孔侧壁间缝隙自下而上流动,待加工工件6接电源正极,工具电极A接负极,处于电解液包围的待加工工件6与工具电极A的金属导电部之间形成电解加工区,工件表面材料在电场作用下被去除,根据工具电极A周围电场分布规律,正对工具电极A的金属导电部电场强度呈现对称弧形,因此处于工具电极A阴极裸露金属材料附近的工件表面材料腐蚀速度呈现中间快、两侧慢的规律,最终光孔被加工成圆形竹节孔即竹节孔的横截面为圆形截面8;之后将工具电极A取出,在相对应的位置插入工具电极B10,再次进行二次电解加工,由于工具电极B轴向前后两侧涂覆了绝缘材料含15%SiC的光敏树脂,使得已加工的圆截面竹节孔内侧仅部分区域再次得到电解腐蚀,在工具电极B10电解加工的过程中,通过控制机床主轴带动工具电极B10进行一定角度,如设定角度为30°~60°往复摆动,同时设置一定的加工电压与通电时间,控制该圆形竹节孔处于电解加工区的内壁面得到进一步的腐蚀,圆形竹节孔逐渐形成椭球形竹节孔,椭球形竹节孔的横截面为椭圆形9。The electrolyte flows from bottom to top along the gap between the tool electrode A and the side wall of the light hole of the workpiece 6 to be processed. The workpiece 6 to be processed is connected to the positive pole of the power supply, and the tool electrode A is connected to the negative pole. The workpiece 6 to be processed and the tool electrode surrounded by the electrolyte The electrolytic machining zone is formed between the metal conductive parts of A, and the surface material of the workpiece is removed under the action of the electric field. According to the electric field distribution around the tool electrode A, the electric field intensity of the metal conductive part facing the tool electrode A presents a symmetrical arc, so it is in the tool The corrosion rate of the surface material of the workpiece near the exposed metal material of the cathode of electrode A shows the law of fast in the middle and slow on both sides. Finally, the light hole is processed into a circular bamboo hole, that is, the cross section of the bamboo hole is a circular section 8; after that, the tool The electrode A is taken out, and the tool electrode B10 is inserted at the corresponding position, and the secondary electrolytic machining is performed again. Since the front and rear sides of the tool electrode B are coated with an insulating material containing 15% SiC photosensitive resin, the processed round-section bamboo Only a part of the inner side of the knot hole is electrolytically corroded again. During the electrolytic machining process of the tool electrode B10, the tool electrode B10 is driven to a certain angle by controlling the spindle of the machine tool. Processing voltage and electrification time, control the circular slub hole in the inner wall of the electrolytic processing area to be further corroded, the circular slub hole gradually forms an ellipsoidal slub hole, and the cross section of the ellipsoidal slub hole is elliptical9 .
实例一:Example one:
1、工具电极的制备。1. Preparation of tool electrodes.
工具电极7包括工具电极A和工具电极B;The tool electrode 7 includes a tool electrode A and a tool electrode B;
工具电极A制备:取一直径为1.5mm,长60mm的圆柱形金属丝,按一定相同距离即等间隔如5mm,沿圆周方向均匀涂覆绝缘胶并紫外光照射下进行固化,再将其固定在机床上,进给浸入到质量浓度为10%的NaNO3电解液中,将涂覆绝缘胶的圆柱形金属丝接电源正极,质量浓度为10%的NaNO3电解液中的铁片接电源负极,施加电压8V,工作时间5min后把金属丝取出,去除金属丝表面的绝缘胶,形成工具电极A的金属导电部即得到工具电极A基体;然后在工具电极A基体的金属表面腐蚀的环形凹槽内涂覆含15%SiC的光敏树脂,放至在紫外光固化机下固化3min后,形成工具电极A的绝缘部,即制备获得工具电极A。Preparation of tool electrode A: Take a cylindrical metal wire with a diameter of 1.5mm and a length of 60mm, and apply insulating glue evenly along the circumferential direction at a certain distance, that is, at equal intervals such as 5mm, and cure it under ultraviolet light, and then fix it On the machine tool, the feed is immersed in a 10 % NaNO3 electrolyte, the cylindrical wire coated with insulating glue is connected to the positive electrode of the power supply, and the iron sheet in the 10 % NaNO3 electrolyte is connected to the power supply Negative electrode, apply a voltage of 8V, take out the metal wire after 5 minutes of working time, remove the insulating glue on the surface of the wire, and form the metal conductive part of the tool electrode A to obtain the tool electrode A substrate; then corrode the ring on the metal surface of the tool electrode A substrate The groove is coated with a photosensitive resin containing 15% SiC, and is cured under an ultraviolet light curing machine for 3 minutes to form an insulating part of the tool electrode A, that is, the tool electrode A is prepared.
工具电极B制备:取一直径为1.5mm,长60mm的圆柱形金属丝,沿其轴向左右两侧绷直涂覆绝缘胶并固化,再将金属丝固定在机床上,进给到配好的10%NaNO3电解液中,将涂覆绝缘胶的圆柱形金属丝或金属管接电源正极,质量浓度为10%NaNO3电解液中的铁片接电源负极,加入工作电压8V,工作时间5分钟后把金属丝取出;在金属丝腐蚀过的前后两侧面涂覆含15%SiC的光敏树脂,并在紫外光固化机下固化3min,待其冷却后取出按等间隔如5mm沿圆周方向均匀涂覆绝缘胶并固化,第二次浸入到质量浓度为10%NaNO3电解液中进行电解腐蚀,由于金属丝的前后两侧具有光敏树脂绝缘的保护,电解过程中只腐蚀金属丝的金属裸露部分逐渐形成弧形凹槽,施加电压8V,工作时间5分钟后,取出金属丝并在弧形凹槽内均匀涂覆含15%SiC的光敏树脂,并在紫外光固化机下固化3min后即制备获得工具电极B。Preparation of tool electrode B: Take a cylindrical metal wire with a diameter of 1.5 mm and a length of 60 mm, stretch it straight along the left and right sides of its axis, apply insulating glue and cure it, then fix the wire on the machine tool, and feed it to the equipped In the 10 % NaNO3 electrolyte, connect the cylindrical metal wire or metal pipe coated with insulating glue to the positive pole of the power supply, and the iron sheet in the electrolyte with a mass concentration of 10 % NaNO3 is connected to the negative pole of the power supply, and add a working voltage of 8V. Take out the metal wire after 5 minutes; coat the photosensitive resin containing 15% SiC on the front and rear sides of the metal wire that have been corroded, and cure it under a UV curing machine for 3 minutes, and take it out at equal intervals such as 5mm along the circumferential direction after cooling down Evenly coat the insulating glue and cure it, and immerse it in the electrolyte solution with a mass concentration of 10 % NaNO3 for the second time for electrolytic corrosion. Since the front and rear sides of the metal wire are protected by photosensitive resin insulation, only the metal of the metal wire will be corroded during the electrolysis process The exposed part gradually forms an arc-shaped groove. Apply a voltage of 8V. After 5 minutes of working time, take out the metal wire and evenly coat the photosensitive resin containing 15% SiC in the arc-shaped groove, and cure it under a UV curing machine for 3 minutes. That is, the tool electrode B is prepared.
2、椭球形竹节孔的加工。2. Processing of ellipsoidal bamboo joint holes.
预先在待加工工件6上加工出孔径2mm,孔深60mm的光孔即光滑通孔,将待加工工件6固定在工作台夹具中,质量浓度为15%NaNO3电解液从光滑通孔自下而上流入;首先将工具电极A进给到待加工工件6上的光滑通孔中,工具电极A接电源负极,待加工工件6接电源正极,施加电压为10V,加工时间为10min,加工结束后将工具电极A取出;接下来工具电极B10再次进给到相同位置进行二次电解加工,施加电压为10V,加工时间10min,其中工具电极B的轴向前后两侧绝缘平面是前后布置的,工具电极B10的导电部在其轴向的左右两侧上。加工过程中工具电极B10作60°角度前后周向往复摆动,加工结束后即得到椭球形竹节孔。Process the workpiece 6 with an aperture of 2mm and a depth of 60mm, i.e. a smooth through hole, and fix the workpiece 6 in the fixture of the workbench. The electrolyte with a mass concentration of 15% NaNO3 flows from the bottom of the smooth through hole. And upward flow; first feed the tool electrode A into the smooth through hole on the workpiece 6 to be processed, the tool electrode A is connected to the negative pole of the power supply, the workpiece 6 to be processed is connected to the positive pole of the power supply, the applied voltage is 10V, the processing time is 10min, and the processing ends Finally, the tool electrode A is taken out; then the tool electrode B10 is fed to the same position again for secondary electrolytic machining, the applied voltage is 10V, and the processing time is 10min. The conductive parts of the tool electrode B10 are located on the left and right sides in the axial direction thereof. During the processing, the tool electrode B10 swings back and forth in the circumferential direction at an angle of 60°, and the ellipsoidal bamboo hole is obtained after the processing is completed.
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Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
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| CN108080753A (en) * | 2018-01-30 | 2018-05-29 | 深圳大学 | The electric discharge device and its processing method of endoporus microflute |
| CN109807412A (en) * | 2019-04-01 | 2019-05-28 | 江西理工大学 | A tool electrode and electrolytic machining device |
| CN115178818A (en) * | 2022-08-18 | 2022-10-14 | 湖南江滨机器(集团)有限责任公司 | Piston pin hole machining method and device and piston |
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| CN106238838B (en) | 2018-02-27 |
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