• CN:11-2187/TH
  • ISSN:0577-6686

›› 2014, Vol. 50 ›› Issue (13): 196-201.

• 论文 • 上一篇    

在线电解修锐-超声珩磨系统多场耦合机理

郐吉才   

  1. 河南理工大学机械与动力工程学院
  • 发布日期:2014-07-05

Coupling Mechanisms of Electrolytic in Process Dressing-ultrasonic Honing System by Multiphisics Code

KUAI Jicai   

  1. School of Mechanical and Power Engineering, Henan Polytechnic University
  • Published:2014-07-05

摘要: 提出在线电解修锐(Electrolytic in process dressing, ELID)-超声珩磨系统,根据多场耦合理论对ELID-超声珩磨系统阴阳极之间电解液的液-声耦合机理进行仿真,并与超声珩磨、普通珩磨进行对比试验。仿真结果表明:ELID-超声珩磨系统电解液耦合速度增加不明显,但是局部速度变化剧烈,使得电极附近电解液更新加快,有利于加快电极双电层的反应离子传质过程,加快离子浓度更新速度,加快电极反应过程;耦合压力变化剧烈,使得电解液更新速度进一步加强;多频率仿真结果显示,超声振动频率在20~25 kHz的范围内耦合效果较好。同时指出:电解电流脉冲频率和超声振动频率保持一致时能得到较好的耦合作用。利用仿真得到的电解参数、超声参数及珩磨参数分别对ZrO2陶瓷进行ELID-超声珩磨、超声珩磨及传统珩磨试验。对比试验结果显示,ELID-超声珩磨系统、超声珩磨及传统珩磨加工精度分别为0.5 µm、1.0 µm和5.0 µm;ELID-超声珩磨系统加工精度较传统珩磨提高9倍,较超声珩磨提高1倍;在其他条件不变的情况下,由于ELID-超声珩磨系统采用新型声学系统,使得振幅减小,因此,加工效率增加不显著。该ELID-超声珩磨系统更适于难加工材料的超精密珩磨加工。

关键词: 在线电解修锐;超声珩磨;多物理场耦合;数值模拟

Abstract: The electrolytic in process dressing (ELID)-ultrasonic honing system is presented. Fluid-ultrasonic coupling mechanisms of electrolyte between electrodes are simulated by multiphisics code. And comparative experimental study on common honing, ultrasonic honing and ELID-ultrasonic honing is proposed. Simulation results show that the coupling velocity of electrolyte of ELID-ultrasonic honing system increases little with increasing ultrasonic frequency, but the local velocity of electrolyte has dramatic changed. Therefore electrolyte updates velocity increases in the vicinity of the electrodes, and reactive ion transfer process increases in electric double layer, and ion concentration updates velocity and electrode reaction process increases. The coupling pressure has dramatic changed, so the electrolyte updates velocity further increases. And multifrequency simulation results show, better coupling effect can be obtained when ultrasonic frequency in 20-25 kHz. At one time point out, the coupling effect is better when the electrolytic pulse frequency coincides with the ultrasonic frequency. The common honing, ultrasonic honing and ELID-ultrasonic honing ZrO2 ceramics are proposed by the electrolytic parameters, ultrasonic parameters and honing parameters, which obtained from the multifrequency simulation. The experimental results show that the ELID-ultrasonic honing precision is 0.5 μm, ultrasonic honing precision is 1.0 μm and common honing precision is 5.0 μm. The honing precision of ELID-ultrasonic honing system is higher 9 times than common honing technology, and higher 1 times than ultrasonic honing technology. Because of using new acoustics system in ELID-ultrasonic honing system, therefore the amplitude is decreased, so processing efficiency increases little with the same technological parameters. The ELID-ultrasonic honing system is suitable for ultraprecision honing of difficult to machining materials.

Key words: electrolytic in-process dressing;ultrasonic honing;multiphysics code;numerical simulation

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