Research On Mechanism And Technology Of Electrochemical Abrasive Jet Machining Based On Compound Energy Field

With the rapid development of modern science and technology, machining demand of component is higher and higher. Therefore, the manufacturing technology faces much challenges, the challenges are two main aspects. One is machining of the complex structural component and special component, traditional processing methods are difficult to process. The other is the machining of new material, traditional processing methods are difficult to process or inefficiently to process. A lot of new processing methods appear in order to meet the requirements. However, the processing methods for difficult-to-cut metal material, metal matrix composite, complex structural component and special component are fewer. Therefore, the development of new processing methods for the requirements has an important significance.This article proposes electrochemical abrasive jet compound machining(ECAJM) technology based on new abrasive jet system. The processing technology is a high precision and high efficient processing method for difficult-to-cut metal material, metal matrix composite. The processing method use the advantages of electrochemical jet machining and abrasive jet machining, the processing method greatly improve processing efficiency to meet the quality of processing. Combining with computer numerical control technology, the processing method can machining complex structure component and special shape component. The key technologies of ECAJM are studied under compound energy field. In this paper, the principle and mechanism of ECAJM are studied under compound energy field. The material removal model of ECAJM is established and the flow field and the electric field are simulated. The set-up of new entrainment abrasive jet system and ECAJM is developed and the experiments of ECAJM are also studied.Based on conservation of energy, the function mechanism of ECAJM is analyzed under the compound field function. Conversion mechanism which is the mechanical energy of abrasive and the elastic deformation energy, plastic deformation and surface energy of materials is analyzed. The research indicates that the mechanical energy of abrasive transforms to the metal elasticity energy, the plastic deformation energy and the surface energy, which enhance the metal electrochemical potential energy, promoting electrochemical jet machining. The coupling mechanism of ECAJM is analyzed. The research indicates that abrasive mechanical action process and electrochemical process is mutual promotion each other in the process of ECAJM. The workpiece surface would form a layer of oxide film with the passivation electrolyte. The oxide film is effectively removed with mechanical abrasive, promoting the electrochemical machining. The bond strength of workpiece surface is reduced for oxide film formation. Workpiece materials are easily removed by abrasive. The efficiency of material removal can greatly improve for interaction. Abrasive mechanical action can improve the homogeneity of the material removal during electrochemical processing, improving the surface quality.The impaction erosion model of abrasive impaction plastic material is established based on the processing mechanism of ECAJM. The removal model of abrasive jet machining is established based on the impaction erosion model of abrasive impaction plastic material and the Finnie model of abrasive plastic shear erosion model, and the experiment of AJM is studied with SKD11. The research indicates that plastic material removal of AJM has both impact erosion removal and shear erosion removal. The removal model of ECAJM is established based on the removal model of abrasive jet machining and the removal model of electrochemical jet machining, and the experiment of ECAJM is studied with SKD11. The research indicates that the material removal rate of ECAJM is greater than the material removal rate of the sum of ECJM and AJM. It is the basis for deterministic removal of ECAJM.The jet flow field is simulated based on the removal model of ECAJM, the distribution of radial velocity and axial velocity of fluid is obtained under different processing parameters. The electric field is simulated within the jet machining area based on the removal model of ECAJM. The distribution of field intensity of workpiece surface is obtained under different process parameters. The flow field and electric field are simulated for electrochemical jet machining rough surface area, discussing the regularity of anodic dissolution and distribution of passivation film of rough surface. The flow field of abrasive is transiently simulated, obtaining distribution and movement of abrasive in the abrasive jet compound process. The abrasive movement mechanism of jet machining region is discussed.The flow field of the new jet system is simulated, the flow field distribution of the new jet system is obtained. The theoretical basis is provided for the development of new jet system. The new entrainment abrasive jet system is developed. It mainly includes pressure supply system, the injection system and the stir and delivery system. The input flow of the abrasive slurry solution and the stability of new entrainment abrasive jet system are tested. The experimental results indicate that the new entrainment abrasive jet system is feasible and mixed evenly. The system achieves precise regulation of abrasive particle concentration. Based on the principle of ECAJM, the set-up of ECAJM is developed. It mainly includes a new entrainment abrasive jet system, machine body and control system, electrochemical machining system and assist device. It carries on experiment of ECAJM, the experimental results indicates that this processing system can get the high processing speed and the surface quality. The experimental set-up of ECAJM is the basis for further processing experiments.Finally, many processing experiments are carried out on the experimental set-up of ECAJM. The effects on both the material removal rate and the surface roughness in ECAJM by the main processing parameters, such as voltage, jet distance, jet pressure, electrolyte concentration, abrasive concentration, abrasive type and size and so on. The range of technical parameters to achieve better results is obtained in ECAJM. Then, it carries on plane experiment of ECAJM, obtaining the good processing plane. The feasibility of the processing method is verified. It indicates the set-up with computer numerical control technology can process difficult-to-cut metal material and metal matrix composite. Therefore, the processing method has the broad application prospect in areas of aerospace and defense industry and so on.