【作者】 韩锋；

【导师】 朱荻；

【作者基本信息】 南京航空航天大学 ， 机械制造及其自动化， 2006， 硕士

【摘要】 整体涡轮技术是一种新型的发动机技术,极大地提高了发动机的性能、效率和可靠性,同时也对制造技术提出了巨大的挑战。电火花加工(Electrical Discharge Machining简称EDM)是基于瞬时脉冲火花放电产生大量的热熔融蚀除金属,是加工整体叶轮的主要工艺方法之一。在整体叶轮的电火花加工中,工具电极的制造是关键。电铸是一种利用金属离子阴极电沉积的原理来制造零部件的工艺技术,具有极高的复制精度和重复精度。对于具有复杂结构型腔、扭曲型面和高精度要求的EDM电极来说,电铸常常是主要甚至是唯一的制造工艺方法。由于电极形状复杂,深宽比大,电铸时电场畸变严重,给电铸工艺的实施带来很大难度。本文研究电铸技术制造整体叶轮电火花加工所用的成型工具电极,完成的主要工作如下:1.基于UG软件平台完成了整体叶轮及其叶片、整体叶轮电火花加工所用的工具电极及其电铸所用的阴极芯模、象形阳极和电场有限元分析模型的造型设计。2.基于ANSYS软件分析了在象形阳极条件下电沉积时两极间的电场分布,提出了增加辅助阳极、涂覆根部圆角等有效措施来改善电场。3.设计了电铸试验系统,开展了电铸制造电火花加工所用工具电极的试验研究。针对试验过程中电场畸变严重造成的沉积失败提出了阴极侧放、根部冲刷、侧面屏蔽、分步电铸等优化工艺措施并成功制备了工具电极。更多还原

【Abstract】 The Integral Impeller is one of the critical components for high performance aero-engine, it is a huge challenge for the modern manufacture.Electrical discharge machining (EDM) is a technology to machine materials by thermal produced instantaneously, and it has many advantages, such as high precision, high surface quality, and without cutting force etc. It is one of the main processing methods for blisk. The fabrication of tool electrodes is the very key in EDM the Integral Impeller.Electroforming has excellent reproductive and repetitive precision in which the metal ion is deposited on cathodic mandrel. This paper focused on the tool electrodes used in EDM fabricated by electroforming and the following work has been done:1. The Integral Impeller with its complicated blades, the electrode used in EDM blisk and the cathodic mandrel were designed by UG software.2. The electric field between the conformal anode and the cathode was analyzed with ANSYS software. The methods, both adding auxiliary anodes and shielding the profiles, were provided to improve the electric field distortion.3. The experimental system was designed. Some new processes, such as leaning the cathode with an angle, washing the bottom, shielding the profiles and continuous stepped electroforming, had been employed to solve the problems appeared in practice. Finally, the tool electrode was fabricated successfully.更多还原