三维复杂曲面电解加工成形规律与阴极闭环设计新方法研究

项目名称： 三维复杂曲面电解加工成形规律与阴极闭环设计新方法研究

项目编号： No.51305219

项目类型： 青年科学基金项目

立项/批准年度： 2014

项目学科： 机械、仪表工业

项目作者： 王蕾

作者单位： 青岛科技大学

项目金额： 25万元

中文摘要： 电解加工是一种特种加工工艺方法，可将具有复杂结构且难切削的导体材料快速加工成型，阴极设计是电解加工技术应用中的复杂且重要的问题。本项目针对三维复杂曲面电解加工阴极设计精度和自动化程度较低的问题，通过深入研究三维复杂间隙空间内曲面电解加工成形规律，提出一种将理论分析得到的工件曲面精度偏差反馈到阴极求解过程的高精度、闭环设计新方法。根据电解加工、流体力学和控制系统等理论，重点研究：①间隙内电场、电解液特性及其流动对成形过程的作用机理；②三维复杂极间间隙内流场参数的分布规律；③工件曲面精度偏差与阴极型面之间的基本映射关系。通过上述基础理论与关键技术的研究，构建三维复杂曲面电解加工成形规律的理论和阴极闭环设计新方法的理论模型，突破阴极设计精度和效率受限难题，进而拓宽电解加工的应用领域。

中文关键词： 电解加工；成形规律；阴极闭环设计；复杂曲面；

英文摘要： Electrochemical machining (ECM) is an effective method for machining all electric-conductive materials into complicated surfaces with high machining rate. The cathode design is the key and difficult problem that ECM technology should be solved first. Aiming at problems of low precision and low efficiency in cathode desing for three dimensional complex curved surfaces, the proposal presents a new closed-loop method of designing cathode accurately and efficiently. In the method the shape's error of the workpiece's curved surface is fed back to the calculation of the cathode. According to fundamental theories of ECM, electrolyte fluid dynamics and closed-loop control system, there are mainly three research aspects：①the mechanism of electric field, electrolyte's characteristics and flow fluid on efficiency of ECM and shaping process; ②the distribution law of flow fluid factors in complex inter-electrode gap; ③the relationship between the error of curved surface's accuracy and the cathode. Finally the research may provide the theory of forming law for three dimensional curved surfaces in electrochemical machining and the theoretical model of the new closed-loop design method of cathode. This research will contribute to improve the precision and efficiency of cathode design, even to realize the high-precision ECM.

英文关键词： electrochemical machining；forming rule；closed-loop design of cathode tool；complex curved surface；