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基于六维力电解加工间隙在线检测试验研究 总被引:4,自引:0,他引:4
为了实时检测加工间隙,把流体作用在阴极上的六维力作为研究参数:设计通电解液不通电、通电加工两大类工况,从定性和定量两个角度分析六维力与加工间隙之间的关系;并以平面、斜面、叶片型面三种阴极进行试验加工,用最小二乘多变元线性拟合法,分别建立平面、斜面阴极加工的六维力与加工间隙之间的关系方程式,用叶片型面加工数据对建立的关系方程式进行检验与修正,得到最终的修正关系式:分析关系式各参量之间的关系,并得到结论:在15%的误差范围内,关系式可以用于在线检测加工间隙。 相似文献
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针对航空发动机叶片电解加工阴极设计这一具体工程应用,在模型叶片三维实体建模的基础上,着重研究两种阴极设计方法,即基于叶片电解加工实际电场分布的阴极设计有限元数值解法以及同时考虑极间电场和电解液流场特性的阴极设计有限元数值解法。详细地对比了两种阴极设计方法对极间电势分布、间隙分布和阴极边界条件的影响,通过一系列的工艺试验验证了同时考虑电解加工电场和流场特性的阴极设计方法较单纯考虑电场特性的阴极设计方法更全面、更符合电解加工的实际物理过程,因而所设计的阴极更加精确合理。 相似文献
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基于信息融合的电解加工间隙检测 总被引:2,自引:0,他引:2
目前,在电解加工中还没有有效的加工间隙在线检测方法[1]。本文通过采集真实电解加工中阴极表面上来自电解液的平行于机床主轴的力和加工电流,利用小波变换对采集的信号进行处理,提取趋势项。结果发现:随着间隙减小力和加工电流都增大,可以据此间接实现间隙的测量。用力和加工电流经过小波变换提取的趋势项进行信息融合来更好地反映间隙,将它用于方坯加工叶片时采用的全程控制。用神经网络建立数显进给位置与力和电流融合信号之间的非线性映射,使它作为标准曲线以对间隙进行自动的全程控制。 相似文献
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ELECTROCHEMICAL MACHINING OF CURVILINEAR SURFACES 总被引:1,自引:0,他引:1
In this work a theoretical analysis of the ECM process of curvilinear surfaces has been presented. The purpose of this analysis is to predict the shape evolution of the machined object using: a shaping surface of small thickness (flat issue) and a blade of hydrodynamic machine (quasi-three dimensional issue). ECM modeling involves prediction of the machined surface shape evolution and distribution of physical-chemical parameters inside the interelectrode gap. The problem has been solved with the use of an equation of the electrolyte and hydrogen mixture (liquid and gas) flat flow inside the interelectrode gap. After introducing simplifying assumptions for the flow, void fraction distribution and the gap thickness, the equations were solved partly analytically, partly numerically. The obtained solutions for assigned parameters of the machining process are presented graphically in the form of distributions of: static pressure, the mixture flow rate, temperature, void fraction and evolution of the machined surface shape evolution. 相似文献
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In this work a theoretical analysis of the ECM process of curvilinear surfaces has been presented. The purpose of this analysis is to predict the shape evolution of the machined object using: a shaping surface of small thickness (flat issue) and a blade of hydrodynamic machine (quasi-three dimensional issue). ECM modeling involves prediction of the machined surface shape evolution and distribution of physical-chemical parameters inside the interelectrode gap. The problem has been solved with the use of an equation of the electrolyte and hydrogen mixture (liquid and gas) flat flow inside the interelectrode gap. After introducing simplifying assumptions for the flow, void fraction distribution and the gap thickness, the equations were solved partly analytically, partly numerically. The obtained solutions for assigned parameters of the machining process are presented graphically in the form of distributions of: static pressure, the mixture flow rate, temperature, void fraction and evolution of the machined surface shape evolution. 相似文献
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叶片是航空发动机的关键零件,以某型航空发动机转子叶片为研究对象,针对叶片电解加工阴极设计这一工程问题,着重考察了采用非线性电解液进行加工时,电解液的非线性特性对阴极设计的影响.本文首先建立了模型叶片的三维实体造型,在此基础上探讨了电解液的非线性特性对电解加工过程和阴极设计产生影响的机理,通过半实验法与数据库技术相结合的方式有效的将这种非线性特性集成到阴极设计方法中. 相似文献
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对六维力/力矩传感器弹性体结构进行了分析;提出了基于Stewart平台的球铰接分体式弹性体的设计方案;根据力的叠加原理对传感器分别施加单轴力,分析得到最大受力杆;并利用Matlab软件分析计算系数转换矩阵,得到施加的力与六维力之间的转换方程;调整上下平台夹角α、β及杆长L等参数,对传感器结构参数进行优化设计,得到设计数据表;为Stewart六维力传感器结构参数的选择及优化提供了参考依据。 相似文献
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为实现加工间隙的在线检测,建立间隙流场中流体运动的计算模型,分析作用在阴极面上的压力矢量分布, 并构建坐标系进行六维力分解,通过调整加工间隙及进口流速,建立阴极上的六维力与加工间隙之间的关系方程 式,用此关系式来实时检测加工间隙。 相似文献
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Feng Ding Zhengjia He 《The International Journal of Advanced Manufacturing Technology》2011,52(5-8):565-574
Electrochemical machining (ECM) is an important technology in machining difficult-to-cut materials and to shape free-form surfaces. In ECM, material is removed by electrochemical dissolution process, so part is machined without inducing residual stress and without tool wear. To improve technological factors in electrochemical machining, introduction of electrode tool ultrasonic vibration is justifiable. This method is called as ultrasonically assisted electrochemical machining (USAECM). In the first part of the paper, the analysis of electrolyte flow through the gap during USAECM has been presented. Based on computational fluid dynamic methods, multiphase, turbulent and unsteady electrolyte flow between anode and cathode (under assumption that cavitation phenomenon occurs) has been analysed. Discussion of the obtained solutions is the base to define optimal conditions of electrolyte flow in case of USAECM process. The second part of the paper is connected with experimental investigations of USAECM process. Classic experimental verification of obtained results in case of machining is extremely difficult, but influence of the ultrasonic vibration can be observed indirectly by changes in technological factors (in comparison to machining without ultrasonic intensification), whereas results of numerical simulation give possibility to understand reason and direction of technological factors changes. Investigations proved that ultrasonic vibrations change conditions of electrochemical dissolution and for optimal amplitude of vibration gives possibility to decrease the electrode polarisation. 相似文献
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In order to resolve the problem of single machining object existing in traditional electrochemical machining (ECM) with unitary cathode, a grid cathode composed of circular cells is used to produce the workpieces with different shapes. Three types of circular cells, ??1.5 mm, ??2.0 mm, and ??2.5 mm, are utilized to construct the plane, slant, and blade cathode. The material of the cathode and the anode is CrNi18Ti9, and the ingredient of electrolyte is 15% NaCl and 15% NaNO3. The machining balance current and the balance time are acquired and analyzed, the machining process and the workpiece quality are compared between using the grid cathode and the unitary cathode. Moreover, the machining errors and the error reasons of workpiece surface are analyzed. Research shows that the grid cathode can be used to manufacture workpieces with a complex shape, and the workpiece quality is better if the circular cell is smaller. If the circular cell is small enough the workpiece quality is almost equal to it machined by the unitary cathode. 相似文献
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This paper presents the design and experiment of a fully pre-stressed six-axis force/torque sensor with double layers. The structure characteristic of the fully pre-stressed six-axis force/torque sensor is introduced in comparison with the traditional Stewart platform-based force sensor. In order to meet the expected task requirements, an optimal design approach based on the given measurement range of the sensor is proposed with the aim of minimizing the forces of the measuring limbs overall. Considering the optimization objective, the optimal solutions of the structural parameters are obtained. Finally, the sensor prototype is manufactured and the calibration system is developed. The calibration experiment is performed and the results prove the superiority of the sensor structure and the validity of the optimal design method. 相似文献
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A Study on Electrochemical Micromachining for Fabrication of Microgrooves in an Air-Lubricated Hydrodynamic Bearing 总被引:1,自引:1,他引:1
Y.-H. Moon E.-S. Lee J.-W. Park 《The International Journal of Advanced Manufacturing Technology》2002,20(10):720-726
A specially built electrochemical micromachining/pulsed electrochemical micromachining (EMM/PECM) cell, a electrode tool filled
with non-conducting material, a electrolyte flow control system and a small and stable gap control unit, are developed to
achieve accurate dimensions for spindle recesses. Two electrolytes, aqueous sodium nitrate and aqueous sodium chloride are
applied in this study. The former electrolyte has better machinability than the latter because of its ability to change appropriately
to the transpassive state without forming pits on the surface of the workpiece. It is easier to control the machining depth
precisely by micrometer with pulse current than direct current. This paper also presents an identification method for the
machining depth by the in-process analysis of the machining current and interelectrode gap size. The interelectrode gap characteristics,
including pulse current, effective volumetric electrochemical equivalent and electrolyte conductivity variations, are analysed,
based on the model and experiments.
ID="A1"Correspondance and offprint requests to: E.-S. Lee, Department of Mechanical Engineering, Inha University, 253, Yonghyun-Dong, Nam-Gu, Incheon, 402–751, Korea. E-mail:
leees@inha.ac.kr 相似文献
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A.F. Stronach J.A. McGeough W.G. Clark 《International Journal of Mechanical Sciences》1976,18(6):261-268
Measurements have been made of the pressure distribution of the electrolyte solution flowing along the inter-electrode gap during electrochemical machining. A theoretical model for the pressure distribution, which takes into account the growth of the hydrogen gas layer along the cathode electrode, is proposed. A method of solution of the model, based on optimisation techniques, is discussed.The experimental results and the theoretical model are correlated in terms of the variation of the interelectrode gap, thereby providing a prediction of the pressure distribution together with values for gas void fraction index, the slope of the gas bubble layer and the friction factor.A comparison of the measured and predicted pressure variation is presented. Numerical values for the above parameters are then discussed in the light of other observations of the process. 相似文献
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加工间隙的监测与控制是电解加工的一个重要研究内容。本文提出了循环迭代间隙控制方案,根据前次循环中加工状况,对进给速度、进给量进行相应调整。在自行研制的立式电解加工机床上,采用虚拟仪器技术构建了电解加工控制系统。研究了有电解液存在情况下进行对刀(湿对刀)的问题。试验结果表明,在电解液中可以实现精确对刀;循环迭代间隙控制可以快速调整工具进给速度,使之近似等于工件去除速度,从而精确地维持恒定的小间隙。 相似文献