CN102699454A - Electrolytic machining system and method for foamed aluminium buffering and energy adsorbing material - Google Patents
Electrolytic machining system and method for foamed aluminium buffering and energy adsorbing material Download PDFInfo
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- CN102699454A CN102699454A CN2012101493702A CN201210149370A CN102699454A CN 102699454 A CN102699454 A CN 102699454A CN 2012101493702 A CN2012101493702 A CN 2012101493702A CN 201210149370 A CN201210149370 A CN 201210149370A CN 102699454 A CN102699454 A CN 102699454A
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Abstract
The invention discloses an electrolytic machining system and an electrolytic machining method for a foamed aluminium buffering and energy adsorbing material. The electrolytic machining system comprises an electrolytic machining machine tool which is formed by a machining system, a control system, an electrolyte system and a fixture device. Firstly, after a foamed aluminium porous material to be machined is fixed, the distance between the foamed aluminium material and an electrode is regulated; and after each machining parameter is set, the electrolytic machining can be carried out. For the foamed aluminium porous material, compared with a conventional turning, planing and grinding scheme, the technical scheme disclosed by the invention overcomes the deformation and the breakage of the porous structure in the machining process.
Description
Technical field
The present invention relates to the Electrolyzed Processing field, more particularly, particularly a kind of Electrolyzed Processing system and method for foamed aluminium buffering energy-absorbing material.
Background technology
Foamed aluminium is a kind ofly to be matrix, to comprise the light porous metal material of a large amount of holes that with Al or its alloy its primary structure characteristic is that the aperture is big and porosity is higher, makes foamed aluminium become a kind of new structure functional metal materials just because of this characteristic.Foamed aluminium has characteristics such as proportion is little, in light weight, hear resistance is strong, rigidity height, also has the function of buffering energy-absorbing simultaneously, more and more receives the attention of every field such as packed and transported, military protection, Aeronautics and Astronautics.Especially as a kind of buffering energy-absorbing material, be applied to the aspect such as protection and inside configuration filling of the visual plant such as buffering package, satellite, guided missile of fragile goods widely.Compare with other buffering energy-absorbing material, the outstanding advantage of foamed aluminium shows:
(1) under less compression stress effect, can produce strain, thus pass to by the protection object stress value very little, play the favorable protection effect;
(2) can make foamed aluminium reach maximum energy absorption ability through the density of regulating foamed aluminium material;
(3) foamed aluminium does not rebound in absorbing energy process;
(4) foamed aluminium shows as isotropism on macroscopic view, so its energy absorption ability and impact direction are irrelevant.
When receiving foreign impacts load, be easy to deform; Deflection is big and the flow stress level is lower; Can consume a large amount of merits in the compression process; With its change into hilum in the structure distortion, cave in, break, the energy that various forms dissipated such as cell wall friction, thereby absorb extraneous impact energy effectively, this than the characteristic of a large amount of impact energys of absorption low stress level under just as the ideal material of buffering energy-absorbing.From performance, foamed aluminium is a kind of buffering energy-absorbing material of lightweight, but the intensity of foamed aluminium own is not high, is not suitable for independent structural member as buffering energy-absorbing and uses; The intensity of metal hollow pipe itself is high than foamed aluminium, but its buffering energy-absorbing performance is far away from foamed aluminium.In order to give full play to the buffering energy-absorbing advantage of foamed aluminium itself, filled with foam aluminum in hollow metal tube, is obtained foam aluminium sandwich structure spare, become the better composite of buffering energy-absorbing.
At present the research emphasis for foamed aluminium mainly concentrates on its preparation, structure, performance, designs, reduces cost and expands aspect such as its application, seldom relates to the machined aspect of foamed aluminium.In order foamed aluminium to be applied to the buffering energy-absorbing field, just need process the foamed aluminium of difformity size.Because the special pore structure of foamed aluminium makes gross distortion and the destruction that processing technologys such as traditional turning, planing and grinding cause foamed aluminium surface pore structure to make the foamed aluminium after processing not meet the requirement of later process.For this reason, seeking the new processing method of foamed aluminium is the key issue that solution is needed in current foamed aluminium practical application badly.
Summary of the invention
The objective of the invention is to overcome the deficiency of prior art; For this porous material of foamed aluminium; In order to overcome the deformation and failure of loose structure in process; A kind of Electrolyzed Processing system and method that utilizes metal material that anodic solution takes place in electrolyte is provided, obtains to have the special process method of dimensional accuracy.Compare with traditional turning, planing and grinding; Topmost this processing method that is characterised in that of Electrolyzed Processing is a kind of noncontact processing; It is wide to have the range of work, does not receive the restriction of hardness, intensity and the toughness of material itself, simultaneously; This processing method also has remarkable advantages such as productivity ratio height, surface quality be good, is particularly suitable for the processing of difficult-to-machine material.
The object of the invention is achieved through following technical proposals:
A kind of Electrolyzed Processing system of foamed aluminium buffering energy-absorbing material comprises electrolytic machine tool, constitutes by system of processing, control system, electrolyte system and grip device,
Said system of processing is made up of processing power source and machined electrode, and said processing power source adopts the pulse power, for Electrolyzed Processing provides electric energy, forms electrochemical reaction between said machined electrode and the workpiece to be processed and carries out Electrolyzed Processing;
In the said control system control electrochemical machining process, the horizontal and vertical feed speed of the rotary speed of lathe, working electrode, thus reach the required precision of processing;
Said electrolyte system is made up of working liquid container, work liquid pump, working solution loop and filter; Working liquid container is used to store electrolyte, and the work liquid pump provides electrolyte to machining gap, reclaims electrolyte through the working solution loop; While configuration effort liquid filter is with the influence of despumation;
Said grip device is used for clamping workpiece to be processed, and according to the processing request of workpiece, realizes the needed motion of workpiece.
The basic demand that whole Electrolyzed Processing system need reach comprises: (1) electrolytic machine tool should have enough rigidity, necessary corrosion resistance; (2) control system must possess reliable short-circuit protection to guarantee machining accuracy; (3) electrolyte system requires feed flow stable, and has the ability of filtration, processing electrolysate.
Said electrolytic machine tool is to be converted by machine tool, in order to be easy to keep the precision and the rigidity of former lathe, shortens the time of repacking, in retrofit process, keeps the agent structure of original lathe as far as possible.The longest processing length of electrolytic machine tool is 700mm, keeps the piece-holder and the fixture of original lathe, mainly is the clamping for cylindrical foam aluminium, in process, drives the foamed aluminium low speed rotation, to guarantee the circularity of foamed aluminium processing.The cutter that tradition processing is used changes machined electrode into; Realize Electrolyzed Processing through electrochemical reaction between electrode and the workpiece to workpiece; Distance between adjusting electrode and the workpiece is (after the workpiece fixed installation; Through the horizontal and vertical feed speed of control system control electrode, the traverse feed velocity interval is 0.01 ~ 1.08mm/min, and the length feed velocity interval is 0.04 ~ 2.16mm/min), voltage and current (for example adopts the pulse power; Its power supply rated input power is 60KVA, and the working power output current scope is the control of 0 ~ 2000A) realization to Electrolyzed Processing.Between workpiece and machined electrode, form electrochemical reaction; Through electrolyte system between electrolyte environment; Realize the circulation of electrolyte through the work liquid pump; Utilize filter to avoid the influence of impurity simultaneously, wherein the power of electrolyte supply pump is 3.2KW, and the power of electrolyte filtering pump is 0.35KW.
A kind of electrochemical machining method of foamed aluminium buffering energy-absorbing material, carry out according to following step:
(1) foamed aluminium porous material to be processed is fixed;
(2) before the processing beginning, regulate foamed aluminium material and interelectrode distance, and each machined parameters is set;
(3) begin processing, treat that foamed aluminium processes after, arrestment, to processing the foamed aluminium workpiece clean.
In electrochemical machining process, its corresponding machined parameters is as follows:
(1) current density
Current density is important machined parameters in the electrochemical machining process, and the size of current density directly influences the efficient of processing and the surface roughness of material.In the process of reality; Current density can not be too big, and after current density value surpassed certain upper limit, the interpolar heat removes product with erosion to be increased too many; If do not improve the pressure and the electrolyte flow rate of pump simultaneously; Then can cause the anomalies such as evaporation, boiling of processing district electrolyte, cause occurring faults such as short circuit, thereby interrupt process.Therefore, in the electrochemical machining process for the foamed aluminium porous material, confirm that foamed aluminium porous material suitable current density range is at 25 ~ 30A/cm
2
(2) machining voltage
In the electrochemical machining process, machining voltage is meant the potential difference between workpiece anode and the tool cathode, and it is to set up that electric field makes Electrolyzed Processing be able to the energy source that carries out between workpiece anode and the workpiece negative electrode.The definite of machining voltage value need come comprehensive selection according to institute's material processed, shape, size and selected current density.In the foamed aluminium electrochemical machining process, machining voltage is generally 18 ~ 20V.
(3) initial manufacture gap
The difference in given initial manufacture gap can influence the transient process that in electrochemical machining process, reaches equilibrium gap before Electrolyzed Processing, thus the precision of influence processing.To the foamed aluminium porous material, 1.0-2mm is confirmed as in its initial manufacture gap.
(4) feed speed
Electrochemical machining process gathers, and confirming of electrolysis feed speed is main according to the area of institute's rapidoprint and selected initial manufacture gap, also need take all factors into consideration the capacity of voltage simultaneously.For the Electrolyzed Processing of foamed aluminium porous material, its traverse feed velocity interval should be controlled at 0.03 ~ 0.08mm/min, and the length feed velocity interval should be controlled at 0.07 ~ 1.50mm/min.
(5) selection of electrolyte
Electrolyte is the carrier that produces anodic solution in the electrochemical machining process, and correctly selecting electrolyte is the primary condition that realizes Electrolyzed Processing.In electrochemical machining process, mainly the acting as of electrolyte: 1) as the conducting medium delivered current; 2) under electric field action, carry out electrochemical reaction, anodic solution can be carried out smoothly and controlledly; 3) take away electrolysate that produces in the machining gap and heat in time, play and upgrade and cooling effect.Take all factors into consideration the concrete application conditions of various electrolyte, confirm the electrochemical machining process of foamed aluminium porous material, selected electrolyte is that concentration is the NaNO of 25wt% ~ 30wt%
3The aqueous solution.
(6) electrolyte pressure
High pressure, electrolyte stream at a high speed are the prerequisites that guarantees high current density.In order to mate, take away in process electrolysate and the heat that is produced with Rational Parameters such as determined current density, initial manufacture gaps, need to regulate flow velocity and the flow that electrolyte pressure changes electrolyte.Through Theoretical Calculation,, confirm in the electrochemical machining process of foamed aluminium that the pressure of electrolyte is 0.2 ~ 0.4MPa in conjunction with a large amount of engineer testings.
Traditional material processing method mainly contains four kinds of turning, milling, planing and grindings.Since foamed aluminium be by the metallic matrix framework in the space the staggered porous material that constitutes, its matrix inside a large amount of holes that are scattered here and there, these holes are cell structure, surrounded by the metal bone, and these holes all cut apart each other, shape is not of uniform size.Therefore adopt traditional machining mode that the foamed aluminium porous material is added man-hour, very easily cause the surface hole defect structure of foamed aluminium porous material to take place seriously to subside, and total is damaged.As the mode that adopts milling is when processing the foamed aluminium porous material.Because milling process is to rotate to be the master with milling cutter, workpiece is made the cutting working method of feed motion.In this process, the cutting force that milling cutter is applied on the workpiece is periodically variable, because workpiece will inevitably produce vibration in milling process, the foamed aluminium loose structure is damaged.In addition, in the processed process, working angles does not have feed motion, and cutting is intermittently intermittently to carry out, and cutter incision and when cutting off workpiece all has impact load, thereby causes the planing process to have shock and vibration, also causes subsiding of foamed aluminium pore structure easily.
Compare traditional processing method, technical scheme Electrolyzed Processing of the present invention is having significant advantage aspect the processing of foamed aluminium.Because Electrolyzed Processing is to utilize anodic solution takes place in electrolyte metal principle to work the work piece into a kind of non-contacting special process method of shape.The basic process of this processing method is: in the process, keep less gap between electrolysis electrode and the workpiece, electrolyte flows through in the gap.On the gap, apply low-voltage DC, according to Faraday's law, workpiece begins dissolving, and lysate is discharged the processing district by the electrolyte that flows, and electrolysis electrode is to the workpiece constant speed feed, to keep the constant of machining gap.Along with the continuity of process, the workpiece shape will be similar to the shape of duplicating electrolysis electrode, obtain processing needed workpiece appearance and size.Because this method has remarkable advantages such as the range of work is wide, productivity ratio is high, surface quality is good, electrolysis electrode is lossless, is particularly suitable for the processing of difficult-to-machine material, thereby overcomes the deformation and failure of loose structure in process.
Description of drawings
Fig. 1 is the composition sketch map of Electrolyzed Processing of the present invention system, and wherein 1 is working electrode (being electrolysis electrode) for guide rail, 5 for top, 4 for foamed aluminium workpiece, 3 for anchor clamps, 2.
The specific embodiment
Further specify technical scheme of the present invention below in conjunction with specific embodiment.
The electrolytic machine tool that uses is the electrolytic machining special purpose machine tool PHECMC 6132-750 of Dongguan City brightness dish automation Science and Technology Ltd..The machined electrode (being electrolysis electrode) that adopts is made for adopting stainless steel material 1Cr18Ni9Ti, and epoxy resins insulation is pasted in the two sides of electrode.Employed foamed aluminium porous material be with the trade mark be the ZL111 aluminium alloy as matrix material, adopt foam melt method to prepare.The density of this foamed aluminium is 0.65 * 10
3Kg/m
3, its main chemical compositions is as shown in table 1.
The chemical composition (wt%) of table 1 ZL111 aluminium alloy
| Si | Mg | Ti | Mn | Cu | Al |
| 8.0~10.0 | 0.4~0.6 | 0.1~0.35 | 0.1~0.35 | 1.3~1.8 | Surplus |
Carry out the Electrolyzed Processing of foamed aluminium according to the enforcement parameter of following table, the foamed aluminium workpiece does not produce the deformation and failure of loose structure at last, the basic form that keeps before the processing.
More than the present invention has been done exemplary description; Should be noted that; Under the situation that does not break away from core of the present invention, the replacement that is equal to that any simple distortion, modification or other those skilled in the art can not spend creative work all falls into protection scope of the present invention.
Claims (5)
1. the Electrolyzed Processing system of a foamed aluminium buffering energy-absorbing material comprises electrolytic machine tool, it is characterized in that, constitute by system of processing, control system, electrolyte system and grip device,
Said system of processing is made up of processing power source and machined electrode, and said processing power source adopts the pulse power, for Electrolyzed Processing provides electric energy, forms electrochemical reaction between said machined electrode and the workpiece to be processed and carries out Electrolyzed Processing;
In the said control system control electrochemical machining process, the horizontal and vertical feed speed of the rotary speed of lathe, working electrode, thus reach the required precision of processing;
Said electrolyte system is made up of working liquid container, work liquid pump, working solution loop and filter; Working liquid container is used to store electrolyte, and the work liquid pump provides electrolyte to machining gap, reclaims electrolyte through the working solution loop; While configuration effort liquid filter is with the influence of despumation;
Said grip device is used for clamping workpiece to be processed, and according to the processing request of workpiece, realizes the needed motion of workpiece.
2. the Electrolyzed Processing system of a kind of foamed aluminium buffering energy-absorbing material according to claim 1 is characterized in that, said grip device drives the foamed aluminium low speed rotation for the clamping of cylindrical foam aluminium in process, to guarantee the circularity of foamed aluminium processing.
3. the electrochemical machining method of a foamed aluminium buffering energy-absorbing material is characterized in that, carries out according to following step:
(1) foamed aluminium porous material to be processed is fixed;
(2) before the processing beginning, regulate foamed aluminium material and interelectrode distance, and each machined parameters is set;
(3) begin processing, treat that foamed aluminium processes after, arrestment, to processing the foamed aluminium workpiece clean.
4. the electrochemical machining method of a kind of foamed aluminium buffering energy-absorbing material according to claim 3 is characterized in that, in electrochemical machining process, its corresponding machined parameters is following: current density range is at 25 ~ 30A/cm
2Machining voltage is 18 ~ 20V; The initial manufacture gap is 1.0-2mm; The traverse feed velocity interval should be controlled at 0.03 ~ 0.08mm/s, and the length feed velocity interval should be controlled at 0.07 ~ 1.50mm/min; Electrolyte is that concentration is the NaNO of 25wt% ~ 30wt%
3The aqueous solution; The pressure of electrolyte is 0.2 ~ 0.4MPa.
5. electrochemical machining method is in the application of foamed aluminium buffering energy-absorbing material processing field.
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN109482990A (en) * | 2018-11-26 | 2019-03-19 | 南京航空航天大学 | The method that sodium nitrate ethylene glycol electrolyte is used for aluminium electrochemical micromachining |
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| CN200995309Y (en) * | 2007-01-22 | 2007-12-26 | 南京农业大学工学院 | Horizontal digital-controlled electrolytic lathe |
| CN101444860A (en) * | 2007-11-30 | 2009-06-03 | 三星电机株式会社 | Electrolyte for electro-chemical machining of metal product |
| TWI320345B (en) * | 2007-05-02 | 2010-02-11 | Univ Nat Kaohsiung 1St Univ Sc |
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Patent Citations (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US20060108328A1 (en) * | 2004-11-23 | 2006-05-25 | General Electric Company | Methods and systems for monitoring and controlling electroerosion |
| CN200995309Y (en) * | 2007-01-22 | 2007-12-26 | 南京农业大学工学院 | Horizontal digital-controlled electrolytic lathe |
| TWI320345B (en) * | 2007-05-02 | 2010-02-11 | Univ Nat Kaohsiung 1St Univ Sc | |
| CN101444860A (en) * | 2007-11-30 | 2009-06-03 | 三星电机株式会社 | Electrolyte for electro-chemical machining of metal product |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN109482990A (en) * | 2018-11-26 | 2019-03-19 | 南京航空航天大学 | The method that sodium nitrate ethylene glycol electrolyte is used for aluminium electrochemical micromachining |
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Application publication date: 20121003 |