电解快速切割成型加工技术研究

发布时间：2018-09-01 13:54

【摘要】：随着航空航天事业的快速发展,对材料性能要求越来越高,钛合金、高温合金等材料在航空航天中的应用越来越多。通常情况下,锻造毛坯的体积远大于零件的体积,零件体积只有毛坯体积的10%—20%,有些甚至低于5%,粗加工过程材料去除量很大,而且这些材料一般都是难加工材料,材料加工难度大、加工周期长、刀具费用高、昂贵材料浪费严重,整个加工成本居高不下。本文提出了一种采用电解切割加工的方式对材料进行直接分割加工,即将具有复杂外形的零件直接从型材或简单毛坯中直接套料加工而成的全新工艺方法。设计并制作电解切割成型加工工具阴极,逐步优选合理的阴极材料,并对阴极结构进行仿真分析、优化,以保证高的切割效率和较低的材料损失。阴极的宽度和形状可根据被加工对象变化:行盲孔切割时,圆周表面可采用筒状阴极或部分筒状阴极,型腔结构则采用板状阴极或其它组合结构阴极,确保这些阴极在加工过程工作稳定。通过在钛合金TC4、高温合金、高温不锈钢材料进行多次实验,证实了电解直接切割加工技术在对零件进行粗加工时的可行性和高效性,得到稳定加工时电解切割加工的一系列工艺参数,为难加工航空航天材料典型复杂结构的快速切割成型加工提供了理论基础和技术支持。
[Abstract]:With the rapid development of aerospace industry, the requirement of material properties is becoming higher and higher. Titanium alloy, superalloy and other materials are more and more used in aerospace. Normally, the volume of the forged blank is much larger than the volume of the part, the volume of the part is only 10% 20% of the volume of the blank, some even less than 5%, the material removal amount is very large during rough processing, and these materials are generally difficult to process. The material processing is difficult, the processing cycle is long, the cutting tool cost is high, the expensive material waste is serious, the whole processing cost is high. In this paper, a new process method is proposed, in which the material is directly separated by electrolytic cutting, that is, the parts with complex shape are processed directly from profiles or simple blanks. In order to ensure high cutting efficiency and low material loss, the cathode of electrolytic cutting and forming tool is designed and made, and reasonable cathode material is selected and analyzed by simulation and optimization to ensure high cutting efficiency and low material loss. The width and shape of the cathode may vary according to the object being machined: when the blind hole is cut, the circumferential surface may be a cylindrical cathode or a partial cylindrical cathode, while the cavity structure may be a plate cathode or other composite cathode, Make sure these cathodes work stably during processing. Through many experiments on titanium alloy TC4, superalloy and high temperature stainless steel, the feasibility and high efficiency of ECM in rough machining of parts are proved. A series of technological parameters of electrolytic cutting in stable machining are obtained and the theoretical basis and technical support are provided for the rapid cutting and forming of typical complex structures of aerospace materials.
【学位授予单位】：沈阳航空航天大学
【学位级别】：硕士
【学位授予年份】：2017
【分类号】：TG662;TG48

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