钛合金TC4混气电解加工基础试验研究
发布时间：2018-10-15 20:36
【摘要】：混气电解加工是一种在常规电解液中混入一定量有压力的气体进行电解加工的加工方法。相比于常规电解加工技术,混气电解加工可以提高材料的集中蚀除能力、减小毛坯的遗传误差、提高零件的复制精度。半个世纪以来的大量研究工作使混气电解加工技术在锻模型腔和叶片型面的加工中得以成功应用。然而,混气电解加工的机理和间隙内流场分布特性等问题还需进一步明确,并且高速摄像等新技术的发展也为深入研究该问题提供了更为便捷的条件。本文采用钛合金TC4材料开展了混气电解加工技术研究,主要研究内容包括:(1)搭建了含气率可调的气液混合系统。为了使气体和电解液在加工区形成稳定的气液两相流,设计了一套基于文丘里效应的气液混合单元,保证了经由该系统得到的气液两相混合物的均匀程度满足钛合金TC4混气电解加工试验要求。(2)分析了混气电解加工间隙内气液两相流场的分布特性。为了研究混气电解加工的流场特点,模拟实际电解加工环境设计了加工间隙变化的矩形流道,对间隙内的气液两相流动进行高速摄像观测,初步总结了气液两相流随间隙变化的分布特性以及电解液中混入气体对间隙内流场、电导率分布的影响等工艺规律。(3)分析了钛合金TC4材料的混气电化学溶解特性。通过比较分析钛合金TC4材料在静液、常规电解加工条件以及混气电解加工条件等多种环境下的极化曲线和E-t曲线,给出了电解液的流动和气体的混入对钛合金TC4材料电解加工的影响,总结了钛合金TC4在混气电解液中的电解加工特性。(4)开展了钛合金TC4毛坯的混气电解加工基础试验研究。以台阶型的钛合金TC4毛坯为研究对象,进行多种含气率参数的混气电解加工试验研究,考察含气率的变化对钛合金TC4毛坯的整平性能、加工表面质量和杂散腐蚀程度等的影响,结果表明含气率β=0.55左右是混气电解加工钛合金TC4工件较好的参数。(5)开展了钛合金TC4叶片混气电解加工应用研究。以扭曲型面的航空发动机叶片为对象进行优选参数的混气电解加工试验,并与常规电解加工对比,试验结果表明混气电解加工在加工毛坯余量差较大、型面扭曲的零件时具有更好的整平能力与复制精度,加工进入平衡状态更快,加工结束后的型面余量差显著减小,叶片型面精度更高,但表面粗糙度稍有增大。
[Abstract]:Mixed Gas Electrochemical Machining (ECM) is a kind of machining method in which a certain amount of gas with pressure is mixed into conventional electrolyte for ECM. Compared with the conventional ECM technology, mixed gas ECM can improve the concentrated erosion ability of materials, reduce the genetic error of blank, and improve the reproduction accuracy of parts. A great deal of research work in the past half century has made the mixed gas electrolytic machining (ECM) successfully applied in the machining of forging die cavity and blade surface. However, the mechanism of mixed gas ECM and the characteristics of flow field distribution in the gap need to be further clarified, and the development of new technologies such as high-speed video camera also provides a more convenient condition for further study of this problem. The main contents of this paper are as follows: (1) A gas-liquid mixing system with adjustable gas content is set up. In order to form a stable gas-liquid two-phase flow between gas and electrolyte in the processing zone, a gas-liquid mixing unit based on Venturi effect was designed. The uniformity of the gas-liquid two-phase mixture obtained by this system is ensured to meet the requirements of the TC4 mixed gas electrolysis machining test of titanium alloy. (2) the gas-liquid two-phase flow field distribution in the gap of the mixed gas ECM is analyzed. In order to study the flow field characteristics of mixed gas ECM, a rectangular channel with varying gap was designed to simulate the actual ECM environment. The gas-liquid two-phase flow in the gap was observed by high speed camera. The distribution characteristics of gas-liquid two-phase flow along with the gap and the influence of the mixed gas in the electrolyte on the flow field and conductivity distribution in the gap were summarized. (3) the electrochemical dissolution characteristics of titanium alloy TC4 materials were analyzed. The polarization curves and E-t curves of titanium alloy TC4 materials under hydrostatic, conventional ECM and mixed gas ECM conditions were compared and analyzed. The effects of electrolyte flow and gas mixing on the electrochemical machining of titanium alloy TC4 materials are presented, and the electrochemical machining characteristics of titanium alloy TC4 in the mixture electrolyte are summarized. (4) the basic experiments of mixed gas electrochemical machining of titanium alloy TC4 blank are carried out. Taking the step type titanium alloy TC4 blank as the research object, the experiments of mixed gas electrolysis machining with various gas content parameters were carried out, and the effects of the change of the gas content on the leveling performance, machining surface quality and stray corrosion degree of the titanium alloy TC4 blank were investigated. The results show that the gas content 尾 = 0.55 is a good parameter for TC4 workpiece of titanium alloy. (5) the application of mixed gas ECM for titanium alloy TC4 blade is studied. The mixed gas ECM experiment with the aero-engine blade with twisted surface as the object is carried out, and compared with conventional ECM, the test results show that the ECM with mixed gas has a large margin in machining blank. When the shape face is twisted, it has better leveling ability and copying precision, and the machining enters into the balance state more quickly, the residual difference of the shape surface after machining is obviously reduced, the precision of the blade surface is higher, but the surface roughness is slightly increased.
【学位授予单位】：南京航空航天大学
【学位级别】：硕士
【学位授予年份】：2017
【分类号】：TG662
本文编号：2273764
[Abstract]:Mixed Gas Electrochemical Machining (ECM) is a kind of machining method in which a certain amount of gas with pressure is mixed into conventional electrolyte for ECM. Compared with the conventional ECM technology, mixed gas ECM can improve the concentrated erosion ability of materials, reduce the genetic error of blank, and improve the reproduction accuracy of parts. A great deal of research work in the past half century has made the mixed gas electrolytic machining (ECM) successfully applied in the machining of forging die cavity and blade surface. However, the mechanism of mixed gas ECM and the characteristics of flow field distribution in the gap need to be further clarified, and the development of new technologies such as high-speed video camera also provides a more convenient condition for further study of this problem. The main contents of this paper are as follows: (1) A gas-liquid mixing system with adjustable gas content is set up. In order to form a stable gas-liquid two-phase flow between gas and electrolyte in the processing zone, a gas-liquid mixing unit based on Venturi effect was designed. The uniformity of the gas-liquid two-phase mixture obtained by this system is ensured to meet the requirements of the TC4 mixed gas electrolysis machining test of titanium alloy. (2) the gas-liquid two-phase flow field distribution in the gap of the mixed gas ECM is analyzed. In order to study the flow field characteristics of mixed gas ECM, a rectangular channel with varying gap was designed to simulate the actual ECM environment. The gas-liquid two-phase flow in the gap was observed by high speed camera. The distribution characteristics of gas-liquid two-phase flow along with the gap and the influence of the mixed gas in the electrolyte on the flow field and conductivity distribution in the gap were summarized. (3) the electrochemical dissolution characteristics of titanium alloy TC4 materials were analyzed. The polarization curves and E-t curves of titanium alloy TC4 materials under hydrostatic, conventional ECM and mixed gas ECM conditions were compared and analyzed. The effects of electrolyte flow and gas mixing on the electrochemical machining of titanium alloy TC4 materials are presented, and the electrochemical machining characteristics of titanium alloy TC4 in the mixture electrolyte are summarized. (4) the basic experiments of mixed gas electrochemical machining of titanium alloy TC4 blank are carried out. Taking the step type titanium alloy TC4 blank as the research object, the experiments of mixed gas electrolysis machining with various gas content parameters were carried out, and the effects of the change of the gas content on the leveling performance, machining surface quality and stray corrosion degree of the titanium alloy TC4 blank were investigated. The results show that the gas content 尾 = 0.55 is a good parameter for TC4 workpiece of titanium alloy. (5) the application of mixed gas ECM for titanium alloy TC4 blade is studied. The mixed gas ECM experiment with the aero-engine blade with twisted surface as the object is carried out, and compared with conventional ECM, the test results show that the ECM with mixed gas has a large margin in machining blank. When the shape face is twisted, it has better leveling ability and copying precision, and the machining enters into the balance state more quickly, the residual difference of the shape surface after machining is obviously reduced, the precision of the blade surface is higher, but the surface roughness is slightly increased.
【学位授予单位】：南京航空航天大学
【学位级别】：硕士
【学位授予年份】：2017
【分类号】：TG662
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