CN109909566B - Low-temperature environment nesting electrochemical machining cathode system and method - Google Patents
Low-temperature environment nesting electrochemical machining cathode system and method Download PDFInfo
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- 238000003754 machining Methods 0.000 title claims abstract description 45
- 238000000034 method Methods 0.000 title claims abstract description 27
- 239000003507 refrigerant Substances 0.000 claims abstract description 108
- 238000009413 insulation Methods 0.000 claims abstract description 51
- 239000003792 electrolyte Substances 0.000 claims abstract description 50
- 239000007788 liquid Substances 0.000 claims description 45
- 238000003860 storage Methods 0.000 claims description 15
- 230000008569 process Effects 0.000 claims description 9
- 239000000463 material Substances 0.000 claims description 7
- 210000001503 joint Anatomy 0.000 claims description 4
- 239000012774 insulation material Substances 0.000 claims description 3
- 239000007769 metal material Substances 0.000 claims description 3
- 238000005260 corrosion Methods 0.000 abstract description 19
- 230000007797 corrosion Effects 0.000 abstract description 19
- 230000009286 beneficial effect Effects 0.000 abstract 1
- 230000000694 effects Effects 0.000 description 6
- 239000007789 gas Substances 0.000 description 5
- 230000009471 action Effects 0.000 description 4
- 230000005684 electric field Effects 0.000 description 4
- 238000003672 processing method Methods 0.000 description 4
- 239000002245 particle Substances 0.000 description 3
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 2
- 238000005299 abrasion Methods 0.000 description 2
- 238000009826 distribution Methods 0.000 description 2
- 230000008014 freezing Effects 0.000 description 2
- 238000007710 freezing Methods 0.000 description 2
- 238000007789 sealing Methods 0.000 description 2
- 241000878007 Miscanthus Species 0.000 description 1
- 229910001069 Ti alloy Inorganic materials 0.000 description 1
- 238000009825 accumulation Methods 0.000 description 1
- 230000002411 adverse Effects 0.000 description 1
- 229910045601 alloy Inorganic materials 0.000 description 1
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- 230000015572 biosynthetic process Effects 0.000 description 1
- 239000004020 conductor Substances 0.000 description 1
- 230000007123 defense Effects 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 238000009792 diffusion process Methods 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 239000011810 insulating material Substances 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 230000007246 mechanism Effects 0.000 description 1
- 229910052757 nitrogen Inorganic materials 0.000 description 1
- 230000001681 protective effect Effects 0.000 description 1
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- 238000005057 refrigeration Methods 0.000 description 1
- 230000000630 rising effect Effects 0.000 description 1
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- 238000007514 turning Methods 0.000 description 1
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Abstract
The invention provides a low-temperature environment nesting electrochemical machining cathode system and method, and belongs to the technical field of electrochemical machining. The cathode system mainly comprises a cathode sheet, a cathode body, a heat insulation sleeve, an insulation sleeve and a refrigerant cavity sleeve. In the trepanning electrochemical machining method, a workpiece is gradually sleeved in an insulating sleeve, refrigerant is delivered to a refrigerant cavity sleeve around a machined part of the workpiece, and local low-temperature areas distributed in a gradient mode are formed around the machined part of the workpiece. The invention is beneficial to reducing the conductivity of the stray electrolyte, reducing the stray corrosion of the machined area of the workpiece and improving the forming precision of the workpiece.
Description
Technical Field
The invention relates to the technical field of electrolytic machining, in particular to a low-temperature environment nesting electrochemical machining cathode system and method.
Background
With the increasing requirements on material performance in national defense and military, aviation and aerospace industries, materials difficult to process such as titanium alloy, high-temperature alloy and the like are applied more and more widely. The traditional machining method has the problems of easy abrasion of a cutter, low machining efficiency, poor surface machining quality, high machining cost and the like in difficult-to-machine materials. Compared with the traditional mechanical processing, the electrochemical processing has the advantages of simple processing process, high processing efficiency, no tool abrasion, no residual stress and the like, and is widely applied to the manufacturing process of difficult-to-process materials. The trepanning electrochemical machining is used as an efficient electrochemical machining mode in electrochemical machining, and particularly plays an important role in forming of the equal straight-line workpieces. However, in the electrochemical machining of the trepanning, the stray corrosion has great adverse effect on the surface quality of the workpiece, because of the existence of the stray electrolyte, the stray corrosion is continuously caused to the machined part of the workpiece by the stray current, the workpiece is subjected to uneven corrosion, the surface machining amount is inconsistent, conicity is generated, and the surface quality is seriously reduced.
Although electrochemical machining has many advantages in the formation of difficult-to-machine materials, the stray corrosion problem generally exists in the workpiece forming process, and due to the fact that an electric field and electrolyte exist between the workpiece anode and the tool cathode, parts which do not need to be machined on the workpiece are subjected to stray corrosion of non-machined parts under the action of the stray electrolyte and the stray current and the time accumulation effect in the machining process, and the surface quality of the workpiece is affected. In the patent "cathode system and processing method for electrolytic processing of gas insulation protective sleeve material" (the university of aerospace of Nanjing of the applicant of application No. 201710463442.3, inventor Licheng Lanyan Liujia is rising), a method for shielding stray electrolyte and reducing stray corrosion by forming a gas insulation layer on the processed surface of a workpiece by using high-pressure gas is disclosed, but because the pressure of the electrolyte along the flowing direction is gradually reduced, the gas pressure above the electrolyte is distributed along the flowing direction of the electrolyte, the gas-liquid interface distribution is inconsistent, and the gas pressure is not easy to control. In the patent "cathode system and processing method for electrolytic processing of insulation shielding sheathing" (Nanjing aerospace university of the applicant of application No. 201710202429.2, inventor of Hecheng Lanyan silvergrass), a method for shielding stray current and reducing stray corrosion by wrapping insulation particles on the surface of a processed part of a workpiece in the form of a particle film is disclosed, but the size of the insulation particles is influenced by a side gap and is more suitable for processing large-channel workpieces. In the patent of 'freezing auxiliary micro-hole processing method and device based on low-temperature environment' (application number 201510212740.6 applicant Nanjing aerospace university, inventor of longanlang yangzhengxiang chen dingfei), a protection method for improving the micro-hole processing precision and quality by spraying low-temperature liquid nitrogen to the back of a workpiece and adopting auxiliary freezing protection is disclosed.
In the process of trepanning electrochemical machining, a small gap is kept between the workpiece anode and the tool cathode and is respectively connected with a power supply, the current density of the machining gap between the workpiece anode and the workpiece cathode is high, the temperature of the electrolyte is increased along the flow path under the action of joule heat, and the corresponding conductivity is gradually increased along the flow path.
The conductivity of the electrolyte affects the stray corrosion of the non-processing area of the workpiece, and the forming precision of electrolytic processing in the processing area is affected by the processing clearance;
the existing various trepanning electrochemical machining methods still cannot well solve the problems of stray corrosion of the machined molded surface of the workpiece and the temperature rise of the electrolyte along the way, so that a trepanning electrochemical machining device and a trepanning electrochemical machining method which can reduce the stray corrosion of a machined area, reduce the taper, stabilize the temperature of the electrolyte along the way and improve the forming precision of the workpiece are needed.
Disclosure of Invention
The invention aims to solve the problems of stray corrosion caused by stray electrolyte and on-way temperature rise of the electrolyte caused by heat generated during processing in the background technology, and provides a nesting electrochemical processing cathode system and method based on low-temperature environment protection, which can reduce stray corrosion in nesting electrochemical processing, reduce workpiece taper, stabilize on-way temperature of the electrolyte and improve workpiece forming precision.
A low-temperature environment trepanning electrochemical machining cathode system comprises a cathode body, wherein a cathode body cavity which is communicated up and down is formed in the middle inside the cathode body; a cathode sheet is arranged below the cathode body, and a cathode blade groove is processed in the middle of the cathode sheet; the method is characterized in that: an insulating sleeve, a refrigerant cavity sleeve and a heat insulating sleeve are sequentially arranged in the cathode cavity from inside to outside; the insulation sleeve, the refrigerant cavity sleeve and the heat insulation sleeve are all in a structural form that the upper end is closed and the lower end is opened; the refrigerant cavity sleeve is internally provided with a refrigerant storage tank, and the refrigerant storage tank is in a step reduction form from top to bottom; the upper part of one side of the outer wall of the refrigerant cavity sleeve is provided with a refrigerant inlet, and the lower part of the other side of the outer wall is provided with a refrigerant outlet; the cathode system also comprises a refrigerant liquid inlet pipe and a refrigerant liquid outlet pipe; the refrigerant liquid inlet pipe sequentially penetrates through the cathode body and the heat insulation sleeve to be in butt joint with the refrigerant inlet, and the refrigerant liquid outlet pipe sequentially penetrates through the cathode body and the heat insulation sleeve to be in butt joint with the refrigerant outlet.
The processing method of the nesting electrochemical processing cathode system in the low-temperature environment is characterized in that: in the trepanning electrochemical machining method, the flow mode of the electrolyte is a lateral flow mode, namely the electrolyte flows in from a liquid inlet at one end of the workpiece and flows out from a liquid outlet at the other end of the workpiece after flowing through a machining gap between the cathode plate and the workpiece; the cathode system feeds the workpiece, and the machined molded surface of the workpiece is gradually sleeved into a local low-temperature protection area in an insulating sleeve wrapped by a refrigerant cavity sleeve; the refrigerant flows in from the refrigerant cavity sleeve liquid inlet pipe and flows out from the refrigerant cavity sleeve liquid outlet pipe through the refrigerant storage tank, and the refrigerant continuously absorbs the heat around the machined workpiece in the flowing process, so that the low-temperature environment around the machined area of the workpiece is maintained, and the temperature rise of the electrolyte along the process is controlled; the flow of the refrigerant is opposite to the flow direction of the electrolyte; the size of the refrigerant storage tank body is reduced in a stepped manner from top to bottom, and the refrigerant storage tank body is gradually reduced from the liquid inlet hole to the liquid outlet hole, so that the temperature of electrolyte around a workpiece is distributed in a gradient manner from top to bottom and from the liquid inlet hole to the liquid outlet hole.
Advantageous effects
1. The invention can reduce the taper of the machined profile of the workpiece caused by stray corrosion. In the electrochemical machining process of the trepanning, a side gap always exists between the machined profile of the workpiece and the cathode edge groove, electrolyte with certain pressure flows through the side gap to enter the insulating cavity, the electrolyte wraps around the machined profile of the workpiece to form stray electrolyte, stray corrosion is generated on the machined profile of the workpiece to form taper under the action of a stray electric field between the workpiece and a cathode conductor, the higher the conductivity of the electrolyte is, the more obvious the stray corrosion effect is, and the larger the taper of the workpiece is; the temperature of stray electrolyte is locally reduced by a refrigerant surrounding the machined molded surface of the workpiece, the conductivity of the stray electrolyte is reduced, the diffusion effect of a stray electric field is weakened, stray corrosion is inhibited, and the taper of the workpiece is improved.
2. The invention is helpful for improving the forming precision of the workpiece. In the electrolytic machining process, the current density of a machining gap between the anode and the cathode of the workpiece is very high, the temperature of the electrolyte is increased along the flow path under the action of Joule heat, and the corresponding conductivity is gradually increased along the flow path. The temperature of the electrolyte is gradually increased from an inlet to an outlet, particularly during high-current density machining, the heating of the electrolyte causes the machining gap to be increased and gradually changes along the flow path, the on-path corrosion of a workpiece is uneven, and the electrochemical machining forming precision is reduced; the refrigerant around the processing gap can inhibit the temperature rise of the electrolyte along the way, the temperature field distribution of the electrolyte along the way is more uniform, the corrosion of the workpiece along the way is more uniform, and the forming precision is improved.
The low-temperature environment jacking electrochemical machining cathode system is characterized in that: the heat insulation sleeve consists of a heat insulation cylinder and a heat insulation ring plate; the heat insulation cylinder is positioned above the heat insulation ring plate, and the upper end of the heat insulation ring plate is provided with an edge structure extending inwards; the edge structure at the upper end of the heat insulation ring plate is matched and positioned with the edge mechanism at the lower end of the insulation sleeve; the refrigerant cavity sleeve is embedded among the heat insulation cylinder, the heat insulation ring plate and the insulation sleeve. The insulating sleeve can further weaken the influence of stray electric fields, and the heat-insulating cylinder and the heat-insulating ring plate can reduce unnecessary heat exchange loss.
The low-temperature environment jacking electrochemical machining cathode system is characterized in that: the heat insulation sleeve, the refrigerant liquid inlet pipe and the refrigerant liquid outlet pipe are heat insulation materials; the refrigerant cavity sleeve is made of heat-conducting metal materials. The refrigerant liquid inlet pipe and the refrigerant liquid outlet pipe are made of heat-insulating materials, so that the refrigeration effect of the refrigerant can be improved.
The low-temperature environment jacking electrochemical machining cathode system is characterized in that: the refrigerant cavity sleeve consists of a cylinder structure and a cover plate structure. The refrigerant cavity sleeve is made of the cylinder part and the cover plate respectively, and convenience and economy of part processing are facilitated.
Drawings
FIG. 1 is a schematic view showing a refrigerant transport mode and an electrolyte flow mode in a cathode assembly according to the present invention;
FIG. 2 is a schematic diagram of the side refrigerant delivery and electrolyte flow patterns of the cathode assembly of the present invention;
FIG. 3 is a schematic view of a refrigerant reservoir;
number designation in the figures: 1-workpiece, 2-cathode sheet, 3-insulating cavity, 4-cathode body, 5-refrigerant liquid inlet pipe, 6-insulating sleeve, 6-1-insulating cylinder, 6-2 insulating ring plate, 7-refrigerant cavity sleeve, 7-1 refrigerant cavity sleeve cover plate, 7-2 refrigerant storage tank, 7-3 refrigerant inlet, 7-4 refrigerant outlet, 8-refrigerant liquid outlet pipe, 9-electrolyte inlet and 10-electrolyte outlet.
Detailed Description
The technical scheme of the invention is further explained in detail by combining the attached drawings:
as shown in figures 1, 2 and 3, the low-temperature environment nesting electrochemical machining cathode system is characterized by comprising a cathode sheet 2, an insulating sleeve 3, a cathode body 4, a refrigerant liquid inlet pipe 5, an insulating sleeve 6, an insulating cylinder 6-1, an insulating annular plate 6-2, a refrigerant cavity sleeve 7, a refrigerant cavity sleeve cover plate 7-1, a refrigerant storage tank 7-2, a refrigerant inlet 7-3, a refrigerant outlet 7-4 and a refrigerant liquid outlet pipe 8; an electrolyte inlet 9; an electrolyte outlet 10;
a through cavity is processed in the middle of the inside of the cathode body 4, holes are respectively formed in the left side and the right side of the cathode body and communicated with the middle cavity, and threaded holes are formed in the bottom of the cathode body;
the bottom surface of the insulating sleeve 3 is in contact with the upper surface of the cathode plate, the outer surface of the insulating sleeve is in contact with the inner surface of the refrigerant cavity sleeve 7, the insulating sleeve is positioned through the clamping groove on the inner side of the heat insulation annular plate 6-2, and the insulating sleeve is integrally embedded into the inner side of the refrigerant cavity sleeve 7;
the middle of the cathode sheet 2 is provided with a cathode edge groove slightly larger than the outline of the workpiece 1, and the cathode edge groove is connected with the bottom surface of the cathode body 4 through a threaded hole;
the inner side of the heat insulation annular plate 6-2 is provided with a clamping groove, the shape and size of the heat insulation annular plate are the same as those of the middle cavity of the cathode body 4, the heat insulation annular plate is embedded into the cavity of the cathode body 4, and the bottom surface of the heat insulation annular plate is contacted with the upper surface of the cathode sheet 2;
the left side and the right side of the heat insulation cylinder 6-1 are respectively provided with a threaded through hole corresponding to the side inlet hole and the liquid outlet hole of the cathode body 4, the threaded through holes are embedded into the through cavity of the cathode body 4, and the bottom surface of the heat insulation cylinder is contacted with the heat insulation annular plate 6-2;
the refrigerant cavity sleeve 7 is provided with a refrigerant inlet 7-3 and a refrigerant outlet 7-4 which correspond to the heat insulation cylinder 6-1 on two sides respectively, a refrigerant storage tank 7-2 is processed in the middle, the storage tank is reduced in a step from top to bottom, is gradually reduced from the refrigerant inlet 7-3 to the refrigerant outlet 7-4 and is embedded into the inner cavity of the heat insulation cylinder 6-1;
the refrigerant cavity sleeve cover plate 7-1 is welded to the upper end of the refrigerant cavity sleeve 7 after being processed and is used for sealing the refrigerant storage tank 7-2;
the refrigerant liquid inlet pipe 5 and the refrigerant liquid outlet pipe 8 are provided with liquid inlet channels in the middle, and are provided with external threads at one end and are respectively connected with threaded holes on the heat insulation cylinder 6-1 through two side holes of the cathode body 4;
the refrigerant liquid inlet pipe 5, the refrigerant liquid outlet pipe 8 and the heat insulation 6 are heat insulation materials, so that heat transfer between the refrigerant liquid and the outer side is reduced;
the refrigerant cavity sleeve 7 is made of metal material with good heat conductivity, and heat transfer is easy;
the electrolyte inlet 9 and the electrolyte outlet 10 are respectively an inlet and an outlet for flowing electrolyte;
the main steps of the invention for electrolytic machining of the workpiece mainly comprise the following processes:
step 1) mounting a cathode system on a cathode rod through a tailstock, wherein the cathode rod is connected with a feeding shaft of a machine tool;
step 2), installing a workpiece;
step 3), tool setting, determining the correct position of the cathode sheet relative to the workpiece machining surface, and setting a proper initial gap;
step 4), fixing the sealing clamp on the cathode through a bolt;
step 5), connecting the anode of a power supply with a workpiece through a lead block, and connecting the cathode of the power supply with a cathode;
step 6), connecting the refrigerant circulating system with a secondary refrigerant cavity sleeve liquid inlet pipe and a secondary refrigerant cavity sleeve liquid outlet pipe respectively;
step 7), opening an electrolyte circulating system, and adjusting the pressure of an electrolyte inlet to a proper value;
step 8), opening a refrigerant circulating system, introducing a refrigerant from a refrigerant cavity sleeve liquid inlet pipe, and leading out the refrigerant from a refrigerant cavity sleeve liquid outlet pipe;
step 9), turning on a power switch, and feeding the machine tool to the workpiece axially;
step 10), feeding the machine tool to a preset distance according to a preset speed;
and 11) stopping feeding of the cathode of the machine tool after the machining is finished, stopping circulating and conveying of the refrigerant, and closing a power supply and electrolyte circulating system.
Claims (5)
1. A low-temperature environment trepanning electrochemical machining cathode system comprises a cathode body (4), wherein a cathode body cavity which is communicated up and down is formed in the middle inside the cathode body (4); a cathode sheet (2) is arranged below the cathode body (4), and a cathode blade groove is processed in the middle of the cathode sheet (2); the method is characterized in that:
an insulating sleeve (3), a refrigerant cavity sleeve (7) and an insulating sleeve (6) are sequentially arranged in the cathode cavity from inside to outside; the insulation sleeve (3), the refrigerant cavity sleeve (7) and the heat insulation sleeve (6) are all in a structural form that the upper end is closed and the lower end is opened; the refrigerant cavity sleeve (7) is internally provided with a refrigerant storage tank (7-2), and the cross section of the refrigerant storage tank is in a form of reducing from top to bottom; a refrigerant inlet (7-3) is arranged at the upper part of one side of the outer wall of the refrigerant cavity sleeve (7), and a refrigerant outlet (7-4) is arranged at the lower part of the other side of the outer wall;
the cathode system also comprises a refrigerant liquid inlet pipe (5) and a refrigerant liquid outlet pipe (8); the refrigerant liquid inlet pipe (5) sequentially penetrates through the cathode body (4) and the heat insulation sleeve (6) to be in butt joint with the refrigerant inlet (7-3), and the refrigerant liquid outlet pipe (8) sequentially penetrates through the cathode body (4) and the heat insulation sleeve (6) to be in butt joint with the refrigerant outlet (7-4).
2. The low-temperature environment trepanning electrochemical machining cathode system of claim 1, wherein:
the heat insulation sleeve (6) consists of a heat insulation cylinder (6-1) and a heat insulation ring plate (6-2); the heat insulation cylinder (6-1) is positioned at the inner side of the heat insulation ring plate (6-2), and the upper end of the heat insulation ring plate (6-2) is provided with an edge structure extending inwards; the edge structure at the upper end of the heat insulation ring plate (6-2) is matched and positioned with the edge structure at the lower end of the insulation sleeve (3);
the refrigerant cavity sleeve (7) is embedded among the heat insulation cylinder (6-1), the heat insulation annular plate (6-2) and the insulation sleeve (3).
3. The low-temperature environment trepanning electrochemical machining cathode system of claim 1, wherein:
the heat insulation sleeve (6), the refrigerant liquid inlet pipe (5) and the refrigerant liquid outlet pipe (8) are heat insulation materials;
the refrigerant cavity sleeve (7) is made of heat-conducting metal materials.
4. The low-temperature environment trepanning electrochemical machining cathode system of claim 1, wherein:
the refrigerant cavity sleeve (7) consists of a cylinder structure and a cover plate structure.
5. The method for processing the cathode system by the set material electrolytic processing in the low-temperature environment according to claim 1, which is characterized in that:
in the trepanning electrochemical machining method, the flow mode of the electrolyte is a lateral flow mode, namely the electrolyte flows in from an electrolyte inlet (9) at one end of the workpiece (1), flows through a machining gap between the cathode sheet (2) and the workpiece (1) and then flows out from an electrolyte outlet (10) at the other end of the workpiece (1);
the cathode system feeds the workpiece (1), and the machined molded surface of the workpiece (1) is gradually sleeved into a local low-temperature protection area in the insulating sleeve (3) wrapped by the refrigerant cavity sleeve (7); a refrigerant flows in from a refrigerant cavity sleeve liquid inlet pipe (5) and flows out from a refrigerant cavity sleeve liquid outlet pipe (8) through a refrigerant storage tank, the refrigerant continuously absorbs heat around the machined workpiece in the flowing process, the low-temperature environment around the machined area of the workpiece (1) is maintained, and the temperature rise of electrolyte along the process is controlled; the flow of the refrigerant is opposite to the flow direction of the electrolyte;
the size of the refrigerant storage tank body is reduced in a stepped manner from top to bottom, and the refrigerant storage tank body is gradually reduced from the liquid inlet hole to the liquid outlet hole, so that the temperature of electrolyte around the workpiece (1) is distributed in a gradient manner from top to bottom and from the liquid inlet hole to the liquid outlet hole.
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