| The groove structure is widely used in aerospace engines,automobile and ships,electronic components,medical equipment and other components.With the rapid development of technology,the demand for meso-mechanical manufacturing parts in a wide range of materials is increasing.Due to the wide application of high-strength composite materials and the diversity of their structures and sizes,most traditional processing methods have been difficult to meet the requirements.Electrochemical milling technology is based on the principle of electrochemical anode dissolution.The non-contact removal of materials is achieved by redox reaction,which is not affected by the mechanical properties of the material and the tool has no wear.Combined with the advantages of CNC milling,the flexibility is improved.The step of designing a dedicated cathode shortens the processing cycle.At the same time,the high-speed rotation of the tool cathode contributes to the discharge of the electrochemical product between the electrodes,so that the processing stability is improved,Therefore,the process has broad application prospects in the field of complex groove and thin-walled groove structure.In this paper,the electrochemical milling process of slot structure is taken as the research object,and the design and construction of the electrochemical milling machining experiment platform is carried out.Based on the experiment platform,the experimental research on electrochemical milling of groove structure is carried out.The specific research contents mainly include the following aspects:1.Theoretical analysis and cathode structure design.Based on the characteristics of groove structure and electrochemical milling,the factors affecting the stability and machining accuracy of electrochemical milling machining of groove structure are analyzed.The flow field distribution of machining region of different structure cathodes is simulated and analyzed based on ANSYS finite element simulation software.The thickness of the bottom end face,the ratio of the inlet and outlet,and the liquid groove distribution in the side wall are optimized.2.Electrochemical milling processing experiment platform construction.Comparing the realization scheme of the rotating liquid-conducting function,the hollow electric spindle,the conductive slip ring and the rotary joint are used to realize the rotary liquid-conducting conductive function finally.At the same time,according to the technical requirements of the electrochemical milling processing,the electrolyte circulating filter system and the power supply system are built.An electrochemical milling experiment system that meets the requirements of process experiment established finally.3.Experimental research on electrochemical milling of meso-mechanical manufacturinggroove structure.Based on the results of theoretical analysis and simulation analysis,a single-factor comparison experiment of different cathode structures and different processing parameters was carried out.By analyzing the maximum stable feed rate that can be achieved by different cathode structures,the previous theoretical analysis of the influence of cathode structure on processing stability was verified.Through the single-factor comparison experiment of different processing parameters,the effects of various parameters on the stability and machining accuracy of electrolytic milling were analyzed.Finally,orthogonal experiment analysis is carried out,and the combination of process parameters is selected,and the thin-walled return groove sample that meets the experiment requirements is processed.The above research explores the straight groove structure of electrolytic milling,and realizes the efficient and stable processing of the low-rigidity and thin-walled groove structure,which lays a foundation for the popularization and application of the process. |
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