【作者】 薛兆云；

【导师】 康敏； 干为民；

【作者基本信息】 南京农业大学 ， 机械设计及理论， 2007， 硕士

【摘要】 传统机械光整加工存在工艺复杂、表面质量差、生产效率低等问题，无法适应目前对零部件加工表面高精度、高质量的要求。脉冲电化学复合光整加工技术主要是以溶解的形式去除工件表层金属，在整个加工过程中切削力和切削热的作用很小。因此，利用脉冲电化学复合光整加工技术加工的工件表面无附加切削痕迹、塑性变形层，与机械加工表面相比，它能大幅度降低表面粗糙度值，进而改善零件表面质量。本文在构建实验装置的基础上，做了大量的工艺试验，对脉冲电化学复合光整加工技术做了深入的研究。本文构建了脉冲电化学复合光整加工试验装置，并分别设计了移动式、旋转式手动光整附件，研发出旋转导电器。针对模具材料718H和NAK80进行一系列的基础工艺试验，选择合适的研磨层，得出两种适合此类材料的电解液配方，该配方具有低成本、无毒、效果显著、性能良好等优点。对直流与脉冲电流两种电化学复合光整加工进行对比试验，试验结果表明，高频脉冲电流复合光整加工通过改善光整的电化学流场，对电解液进行搅拌，从而改善光整产物的排放状况，有效提高光整后的工件表面质量。在此基础上，重点考察了脉冲电化学复合光整加工过程中各工艺参数对光整后表面粗糙度的影响，如：脉冲频率、占空比、峰值电压、光整时间等，由此获得了这两种模具材料在整个过程中的基本工艺规律，并通过正交试验对光整加工中的各参数进行优化。最后结合CAD／CAM技术，运用Pro／E软件进行复杂曲面的NC加工仿真，为脉冲电化学复合光整加工技术推广到三维复杂曲面作前期准备，以使该技术的研究更深入、应用范围更广泛。更多还原

【Abstract】 Due to the production problems such as poor quality, low efficiency during machining of complex surface, traditional mechanical finishing is unable to adapt to the demands of the high precision and the quality surface of parts. Pulse electrochemical compound finishing technology removes the metal from the surface by electrochemical dissolution with less cutting force and heat, so there is no cutting mark, plastic deformation layer on the surface of the parts compare to traditional machining. Therefore it can greatly reduce the values of surface roughness and improve the surface quality of parts. On the basis of building experimental foundations and through massive experiments, we made deep research on the pulse electrochemical compound finishing technology in this paper.The equipment of pulse electrochemical compound finishing was constructed, the removal and the rotary manual finishing accessories were designed separately, and the revolving conductor appliance was developed for the testing. Selecting appropriate attrition level and carrying a series of basic technology experiments on mold material 718H and NAK80, two kinds of electrolyte which suit this kind of material were obtained. There are many merits, such as the low cost, non-toxic, the remarkable effect, the good performance of them. With contrast experiment between direct-current and pulse current electrochemical compound finishing, the result indicated that this technology can improve the scrap emission condition and enhance their surface quality effectively, because this technology improved the finishing electrochemical flow field and mixed round the electrolyte.On this paper, the pulse electrochemical compound finishing technology parameters which influence the finishing surface roughness was paid attention to, such parameters include the pulse frequency, the duty factor, the peak voltage, the finishing time and so on. Then basic craft rule of two kinds of mold material in finishing process were obtained, and each kind of parameter in this craft was optimized by means of the orthogonal experiments.Finally, combining with the CAD/CAM, the NC processing simulation of the complex surface was carried on by the Pro/E software technology, the paper makes prophase preparation for promoting the pulse electrochemical compound finishing technology to the three dimensional complex surface machining. It aims at making the study of this technology deeper and the application area broader.更多还原