Flow Field Design and Experimental Research of ECM of Array Spherical Groove Structures with Variable Cross-sections

doi:10.3969/j.issn.1004-132X.2023.23.006

Abstract

Abstract: Variable cross-section spherical groove structure had high surface hardness and complex 3D shape. ECM had better technical and economic advantages， but the processing accuracy and processing stability were affected by the flow field obviously. In order to improve the uniformity of the electrolyte flow field， the influences of the electrolyte flow mode and channel structure on the flow field distribution were discussed based on the flow field simulation analysis， and the ECM experiments were carried out. The simulation and test results show that the zonal liquid flow in directional channel is conducive to improving the stability of the flow field and the consistency of the flow rate distribution， which may improve the processing stability. Optimization of the inlet and outlet flow channel structures may further improve the surface quality of the spherical groove， which may meet the requirements of machining stability and machining accuracy.

Key words: variable cross-section spherical groove, electrochemical machining（ECM）, flow field design, channel structure

摘要： 变截面球槽结构表面硬度高、三维形状复杂，采用电解加工具有较好的技术经济优势，但其加工精度和加工稳定性受流场影响比较明显。为提高电解液流场均匀性，基于流场仿真分析探讨了通液方式、流道结构对流场分布的影响规律，并开展了电解加工试验研究。仿真和试验结果表明：采用定向流道供液的分域通液方式有利于提高流场稳定性和流速分布一致性，可以有效提高工艺稳定性；优化出入口流道结构可以进一步提高球槽表面质量，能够满足加工稳定性和加工精度要求。

关键词: 变截面球槽, 电解加工, 流场设计, 流道结构

CLC Number:

TG662

YAN Dinghu, ZHAO Jianshe, ZHANG Changhao, GAO Weizheng, ZHU Yin, . Flow Field Design and Experimental Research of ECM of Array Spherical Groove Structures with Variable Cross-sections[J]. China Mechanical Engineering, 2023, 34(23): 2824-2831.

严丁虎, 赵建社, 张昌昊, 高伟正, 朱寅, . 阵列变截面球槽结构电解加工流场设计及试验研究[J]. 中国机械工程, 2023, 34(23): 2824-2831.

References

［1］司小云，马文伦，尹顺良，等. 某轮式车辆盘式驻车制动器设计［J］. 车辆与动力技术， 2017（3）：40-44.
SI Xiaoyun， MA Wenlun， YI Shunliang， et al. Design of Disc Parking Brake of a Certain Wheeled Vehicle［J］. Vehicle and Power Technology， 2017（3）：40-44.
［2］WANG G， SHAN Y. Compensation of Electrode Orbiting in Electrical Discharge Machining Based on Non-uniform Offsetting［J］. International Journal of Machine Tools and Manufacture， 2005， 45（14）：1628-1634.
［3］周叙荣，蒋永锋，干为民，等. 球槽曲面电解加工流场设计及试验研究［J］. 电加工与模具， 2021（4）：36-41.
ZHOU Xurong， JIANG Yongfeng， GAN Weiming， et al. Flow Field Design and Experimental Research on Electrochemical Machining of Billiard Groove Surface［J］. Electrical Machining and Die， 2021（4）：36-41.
［4］尧佳路，张传运，李俊飞，等. 阵列变截面凹坑结构电解成形加工流场设计及试验研究［J］. 电加工与模具， 2019（3）：42-46.
YAO Jialu， ZHANG Chuanyun， LI Junfei， et al. Flow Field Design and Experimental Study on Electrolytic Forming of Array Pit with Variable Cross-section. Electrical Machining and Die， 2019（3）：42-46.
［5］TANG L， FENG X， ZHAI G K， et al. Gap Flow Field Simulation and Experiment of Electrochemical Machining Special-shaped Inner Spiral Tube［J］. The International Journal of Advanced Manufacturing Technology， 2019， 100（9）：2485-2493.
［6］赵建社，王峰，肖雄，等. 微尺度弧形群缝电解加工试验研究［J］. 机械工程学报， 2014， 50（23）：186-193.
ZHAO Jianshe， WANG Feng， XIAO Xiong， et al. Experiment Research on Electrochemical Machining of Micro-scale Arc-shaped Multi-grooves［J］. Journal of Mechanical Engineering， 2014， 50（23）：186-193.
［7］徐家文，云乃彰，王建业. 电化学加工技术：原理·工艺及应用［M］. 北京：国防工业出版社， 2008.
XU Jiawen， YUN Naizhang， WANG Jianye. Electrochemical Machining Technology：Principle， Process and Application［M］. Beijing：National Defense Industry Press， 2008.
［8］FANG X， QU N， ZHANG Y， et al. Effects of Pulsating Electrolyte Flow in Electrochemical Machining［J］. Journal of Materials Processing Tech.， 2014， 214（1）：36-43.
［9］许绝舞，朱栋，朱荻. 扩压器套料电解加工流场优化设计及实验研究［J］. 电加工与模具， 2018（2）：24-28.
XUE Juewu， ZHU Dong， ZHU Di. Optimization Design of Flow Field and Experimental Investigation of the Jacketed Electrochemical Machining for the Diffuser［J］. Electrical Machining and Die， 2018（2）：24-28.
［10］张淑佳，李贤华，朱保林，等. k-ε涡黏湍流模型用于离心泵数值模拟的适用性［J］. 机械工程学报， 2009， 45（4）：238-242.
ZHANG Shujia， LI Xianhua， ZHU Baolin， et al. Applicability of k-ε Eddy Viscosity Turbulence Models on Numerical Simulation of Centrifugal Pump［J］. Journal of Mechanical Engineering， 2009， 45（4）：238-242.

[1]	WANG Yiyu, ZHAO Jianshe, GU Minkai, JI Tao. Flow Field Design and Process Stability in Electrochemical Machining of Involute Internal Splines#br# [J]. China Mechanical Engineering, 2021, 32(13): 1562-1570.
[2]	WANG Feng1,2;ZHAO Jianshe1;LIU Dingming1;FAN Yantao1;TIAN Zongjun1. Experimental Research on Controllable Vibration Assisted ECM of Deep Narrow Grooves of Titanium Alloy [J]. China Mechanical Engineering, 2019, 30(20): 2395-2402.
[3]	ZHOU Xiaochao1,2;CHEN Yuanlong1;HOU Tingbo1;WANG Zhuangzhuang1. Multi physics Coupling Simulation of ECM Based on Gas Liquid Two phase Flow Model [J]. China Mechanical Engineering, 2019, 30(10): 1135-1141.
[4]	PANG Guibing 1;XIN Kaikai 1;CAI Xiao1;JI Tian1;ZHANG Liping1;LIU Jiyu2;HAN Jiwan3. Modeling and Experimental Study of Inter-electrode Gaps in ECM for Planes of Floating Cathode with a Round Mouth [J]. China Mechanical Engineering, 2017, 28(22): 2655-2661.
[5]	Chen Yuanlong, Fang Ming, Pei Di, Chang Weijie. Multi-physics Coupling Simulation of ECM Processes for Compressor Blade [J]. China Mechanical Engineering, 2016, 27(22): 3087-3092.
[6]	Zhao Jianshe, Li Long, Wang Feng, Xiao Xiong. Influence of Tool Vibration Feeding on ECM Process in Machining Micro Multi-grooves [J]. China Mechanical Engineering, 2015, 26(1): 44-48,78.
[7]	Liu Jia, Zhu Dong, Wan Longkai, Zhu Di. Design and Experiments of Slip Seal Structure Cathode in ECM of Blisk [J]. China Mechanical Engineering, 2014, 25(14): 1847-1851.
[8]	Wang Feng, Zhao Jianshe, Jiang Qin, Xiao Xiong. Investigation on Meso Scale Multi-groove Machining by ECM Based on Electric Field Simulation [J]. China Mechanical Engineering, 2013, 24(23): 3154-3158.
[9]	SUN Lun-Ye, XU Zheng-Yang, SHU Di. Cathode Design and Experiments on Radial Feeding in ECM of Blisk Based on Cascade Channel Machinability Analysis [J]. China Mechanical Engineering, 2013, 24(09): 1137-1141.
[10]	FU Xiu-Qing, KANG Min, YANG Yong, LIU Ze-Xiang. Research on Flow Field Simulation and Experiment of NC-ECM with Spherical Cathode [J]. China Mechanical Engineering, 2013, 24(08): 1038-1042.
[11]	ZHANG Hua-1, XU Jia-Wen-2, DIAO Jian-She-2. Simulation and Experimental Research on Jet Electrolytic Drilling [J]. China Mechanical Engineering, 2011, 22(21): 2624-2627.
[12]	XU Wen-Ji-1, DOU Qiang-Le-1, SUN Jing-1, SONG Jin-Long-1, LONG Gui-Bing-2. Study on Fabrication of Superhydrophobic Surface Substrate Based on ECM [J]. China Mechanical Engineering, 2011, 22(19): 2354-2359.
[13]	GONG Ting, XU Zheng-Yang, XU Qiang, SHU Di. Analysis on Cathode Movement Path and Parameters in ECM of Blisk Tunnels [J]. China Mechanical Engineering, 2011, 22(18): 2209-2214.
[14]	Wang Minghuan;Zhu Di;Peng Wei. Research on Turbulated Cooling Hole Machining by ECM Based on FEM [J]. J4, 2009, 20(18): 0-2259.
[15]	Lü Hesheng,;Lin Tengjiao;Zhang Shijun;Li Runfang. 3-D Flow Analysis of Oil Channel in Wet Multi-disc Friction Clutch [J]. J4, 2009, 20(16): 0-2015.