CN115090973B - Electric spark electrolytic composite forming processing method based on water-in-oil emulsion - Google Patents
Electric spark electrolytic composite forming processing method based on water-in-oil emulsion Download PDFInfo
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- CN115090973B CN115090973B CN202210707395.3A CN202210707395A CN115090973B CN 115090973 B CN115090973 B CN 115090973B CN 202210707395 A CN202210707395 A CN 202210707395A CN 115090973 B CN115090973 B CN 115090973B
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- 238000010892 electric spark Methods 0.000 title claims abstract description 51
- 239000007762 w/o emulsion Substances 0.000 title claims abstract description 43
- 239000002131 composite material Substances 0.000 title claims abstract description 30
- 238000003672 processing method Methods 0.000 title claims abstract description 11
- 238000003754 machining Methods 0.000 claims abstract description 42
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims abstract description 29
- 239000003792 electrolyte Substances 0.000 claims abstract description 9
- 239000000463 material Substances 0.000 claims abstract description 9
- 239000012530 fluid Substances 0.000 claims description 25
- 239000003995 emulsifying agent Substances 0.000 claims description 10
- 239000000839 emulsion Substances 0.000 claims description 9
- 238000011010 flushing procedure Methods 0.000 claims description 8
- 150000003839 salts Chemical class 0.000 claims description 8
- 239000003921 oil Substances 0.000 claims description 7
- 239000008367 deionised water Substances 0.000 claims description 6
- 229910021641 deionized water Inorganic materials 0.000 claims description 6
- 239000002480 mineral oil Substances 0.000 claims description 6
- 235000010446 mineral oil Nutrition 0.000 claims description 6
- 239000007787 solid Chemical class 0.000 claims description 6
- 238000002156 mixing Methods 0.000 claims description 5
- FAPWRFPIFSIZLT-UHFFFAOYSA-M Sodium chloride Chemical class [Na+].[Cl-] FAPWRFPIFSIZLT-UHFFFAOYSA-M 0.000 claims description 4
- 229940051841 polyoxyethylene ether Drugs 0.000 claims description 4
- 229920000056 polyoxyethylene ether Polymers 0.000 claims description 4
- 239000012266 salt solution Substances 0.000 claims description 4
- 238000003756 stirring Methods 0.000 claims description 3
- 238000001816 cooling Methods 0.000 claims description 2
- 235000014113 dietary fatty acids Nutrition 0.000 claims description 2
- 239000000194 fatty acid Substances 0.000 claims description 2
- 229930195729 fatty acid Natural products 0.000 claims description 2
- 239000011259 mixed solution Substances 0.000 claims description 2
- 239000002245 particle Substances 0.000 claims description 2
- 239000011780 sodium chloride Substances 0.000 claims description 2
- -1 sorbitan fatty acid ester Chemical class 0.000 claims description 2
- 238000002360 preparation method Methods 0.000 claims 1
- 230000009977 dual effect Effects 0.000 abstract description 3
- 230000001105 regulatory effect Effects 0.000 abstract description 2
- 238000000034 method Methods 0.000 description 12
- 239000012224 working solution Substances 0.000 description 4
- 230000007547 defect Effects 0.000 description 3
- 238000004090 dissolution Methods 0.000 description 3
- 238000005520 cutting process Methods 0.000 description 2
- 238000010586 diagram Methods 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 238000004519 manufacturing process Methods 0.000 description 2
- 230000002411 adverse Effects 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 150000001875 compounds Chemical class 0.000 description 1
- 230000007797 corrosion Effects 0.000 description 1
- 238000005260 corrosion Methods 0.000 description 1
- 238000007599 discharging Methods 0.000 description 1
- 238000005868 electrolysis reaction Methods 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 150000002500 ions Chemical class 0.000 description 1
- 238000002844 melting Methods 0.000 description 1
- 230000008018 melting Effects 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 238000003801 milling Methods 0.000 description 1
- 239000012768 molten material Substances 0.000 description 1
- 239000011148 porous material Substances 0.000 description 1
- 238000007711 solidification Methods 0.000 description 1
- 230000008023 solidification Effects 0.000 description 1
- 230000007847 structural defect Effects 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23H—WORKING OF METAL BY THE ACTION OF A HIGH CONCENTRATION OF ELECTRIC CURRENT ON A WORKPIECE USING AN ELECTRODE WHICH TAKES THE PLACE OF A TOOL; SUCH WORKING COMBINED WITH OTHER FORMS OF WORKING OF METAL
- B23H5/00—Combined machining
- B23H5/02—Electrical discharge machining combined with electrochemical machining
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23H—WORKING OF METAL BY THE ACTION OF A HIGH CONCENTRATION OF ELECTRIC CURRENT ON A WORKPIECE USING AN ELECTRODE WHICH TAKES THE PLACE OF A TOOL; SUCH WORKING COMBINED WITH OTHER FORMS OF WORKING OF METAL
- B23H5/00—Combined machining
- B23H5/12—Working media
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Electrochemistry (AREA)
- Electrical Discharge Machining, Electrochemical Machining, And Combined Machining (AREA)
Abstract
The invention relates to an electric spark electrolytic composite forming processing method based on water-in-oil emulsion, which utilizes the dual characteristics of insulativity and conductivity of the water-in-oil emulsion to organically combine electric spark forming processing with electrolytic processing; in the machining process, the workpiece material is etched and removed by utilizing the high temperature generated by electric spark forming machining, and the recast layer generated by electric spark machining is removed by utilizing electrolytic machining; the electric spark forming and the electrolytic machining strength are controlled and regulated by different combinations of the water content of the water-in-oil emulsion and the concentration of the aqueous electrolyte, and when the electric spark forming and the electrolytic machining strength reach a proper proportion, the forming and the machining of the high-precision recast-free layer can be realized.
Description
Technical Field
The invention relates to an electric spark electrolytic composite forming processing method based on water-in-oil emulsion, and belongs to the field of special processing.
Background
The electric spark forming process is a special process of melting or gasifying and eliminating workpiece material with the instant high temperature produced by continuous pulse discharge between positive and negative poles. Because it is not limited by the strength and hardness of the workpiece material, the electric spark forming process has been widely used for processing difficult-to-cut materials and parts of complex shape. However, the spark-forming surface typically contains a recast layer formed by solidification of the molten material that has not been thrown off. The recast layer contains structural defects such as microcracks, micro-pores and the like, has larger residual stress, and has serious adverse effects on the performance, reliability and service life of the part.
Electrolytic processing is a special processing method for removing materials by utilizing electrochemical dissolution of a metal anode. The workpiece material is dissolved and removed in the form of ions, and no high heat is generated, so that the electrolytic machining surface has no recast layer, microcracks, micro holes, residual stress and other heat damage defects related to the recast layer, and has the advantages of smooth surface, no burrs and good surface quality. However, electrolytic machining is less localized than electric discharge machining, resulting in poor machining accuracy.
The electric spark electrolytic composite processing method can organically combine the advantages of electric spark processing and electrolytic processing, and realizes the processing with high precision and high surface quality. The working fluid adopted in the electric spark electrolytic composite machining needs to meet the requirements of electric spark machining and electrolytic machining at the same time. The electric spark machining requires a working fluid having good insulating properties to maintain stable spark discharge, so that it generally uses oils as the working fluid; electrolytic processing requires a certain conductivity of the working fluid, and therefore, it is generally performed using a water-based working fluid. Because the working fluids with different characteristics are suitable for different electric machining modes, the working fluids are key factors for realizing organic combination of electric spark machining and electrolytic machining.
At present, water-based working fluid with certain conductivity is generally adopted in electric spark electrolytic composite processing. The water-based working fluid is well applied to processing forms such as micro holes, small holes, wire cutting and the like, and the practical production and application level of the water-based working fluid in the field of forming processing is not achieved. This is because the water-based working fluid has a high conductivity and can meet the requirements of electrolytic machining on the working fluid. However, the water-based working fluid is liable to cause unstable spark discharge between the electrode and the workpiece, and the phenomenon of instability is more remarkable as the machining area is larger, so that the water-based working fluid is mainly applied to an electric spark machining mode with relatively open machining gap and smaller machining area. In the spark forming process with a closed process gap and a large process area, the water-based working fluid is difficult to maintain stably, so that the practical production and application of the spark forming process in the spark electrolysis composite forming process are not achieved yet. It also shows that the existing electric spark electrolytic composite processing method based on the water-based working solution is difficult to solve the forming processing problems of high precision and high surface quality.
Disclosure of Invention
Aiming at the defects of the prior processing technology, the invention provides an electric spark electrolytic composite forming processing method based on water-in-oil emulsion, which utilizes the dual characteristics of insulativity and conductivity of the water-in-oil emulsion to organically combine electric spark forming processing with electrolytic processing, can fully play the advantages of two electric processing modes and realize the forming processing of a high-precision non-recasting layer.
A water-in-oil emulsion is an emulsion system in which the oil is the continuous phase, the water is the dispersed phase, and the water is highly dispersed in the oil in the form of droplets. Because the oil is in an 'outer' phase, the water-in-oil emulsion has good insulating property and can maintain stable electric spark forming processing. Meanwhile, the water-in-oil emulsion has certain conductivity due to the existence of water, so that the smooth electrolytic processing can be maintained. Therefore, the water-in-oil emulsion can meet the requirements of electric spark forming and electrolytic machining on working fluids, and can be used as a dual-purpose working fluid for electric spark forming and electrolytic machining.
The invention is realized by the following technical scheme:
Immersing a workpiece in the water-in-oil emulsion, respectively connecting the workpiece and a tool electrode to the positive electrode and the negative electrode of a pulse power supply, and driving the tool electrode to realize feeding motion by a machine tool spindle; the water-in-oil emulsion is flushed into the processing area to provide fresh working fluid for the processing gap and assist chip removal; in the machining process, the electric spark forming machining and the electrolytic machining coexist, the workpiece material is etched and removed by utilizing the high temperature generated by the electric spark forming machining, and the recast layer generated by the electric spark machining is removed by utilizing the electrolytic machining;
the electric spark forming and the electrolytic machining strength can be controlled and regulated by different combinations of the water content of the water-in-oil emulsion and the concentration of the aqueous electrolyte. Specifically, when the water content of the water-in-oil emulsion and the concentration of the aqueous electrolyte are low, the insulativity of the emulsion is strong, and the electrolytic machining is weak at the moment, so that the electric spark forming machining plays a dominant role; as the water content of the water-in-oil emulsion and the concentration of the aqueous electrolyte increase, the conductivity of the emulsion gradually increases and the electrolytic processing effect gradually increases. When the strength of electric spark forming processing and electrolytic processing reaches a proper proportion, forming processing of a high-precision recast-free layer can be realized;
Further, the water-in-oil emulsion consists of deionized water, solid salt, white mineral oil and a composite emulsifier; the composite emulsifier comprises the following components in percentage by mass: 27 sorbitan fatty acid ester and laurinol polyoxyethylene ether; the mass ratio of deionized water, white mineral oil and composite emulsifier is 2: (3-8): (1-2); the solid salt is formed by combining one or more salts of NaCl, naNO 3, naClO 3 and the like;
further, the water-in-oil emulsion is flushed into the processing area in a flushing mode, which can be an inner flushing, an outer flushing and an inner and outer combined flushing.
The invention has the beneficial effects that:
1. The invention adopts the water-in-oil emulsion as the dual working fluid for electric spark electrolytic composite forming processing, and the working fluid overcomes the defects that the traditional pure oil working fluid can only be used for electric spark forming processing, a recast layer exists on the processing surface, the water-based working fluid can be used for electrolytic processing, but cannot maintain stable electric spark forming processing and is difficult to be used as the electric spark electrolytic composite forming processing working fluid;
2. The invention does not need to change the type of working solution, a power supply system and machine tool equipment in the whole processing process, and can finish the controllable adjustment of electric spark forming and electrolytic processing by changing the water content of the water-in-oil emulsion and the concentration of the aqueous electrolyte, and when the strength of the water-in-oil emulsion and the aqueous electrolyte reach the proper proportion, the forming processing of a high-precision recast layer can be realized;
3. The double-property working solution water-in-oil emulsion provided by the invention is not only suitable for electric spark electrolytic composite forming processing, but also suitable for electric spark electrolytic composite processing modes such as micro processing, small hole processing, milling processing, wire cutting processing and the like.
Drawings
FIG. 1 is a schematic diagram of an electric spark electrolytic composite forming processing method based on water-in-oil emulsion;
the device comprises a machining groove 1, a water-in-oil emulsion 2, a workpiece 3, a tool electrode 4, a machine tool spindle 5 and a pulse power supply 6.
Detailed Description
The following description of specific embodiments of the invention is provided in conjunction with the accompanying drawings, and it should be noted that the specific embodiments and detailed procedures described herein are merely for convenience of description and are not limiting of the invention.
FIG. 1 is a schematic diagram of an electric spark electrolytic composite forming process based on water-in-oil emulsion; the water-in-oil emulsion is placed in a processing tank, and a workpiece is immersed in the water-in-oil emulsion; in addition, the water-in-oil emulsion is flushed into the processing area to provide fresh working fluid for the processing gap and assist in chip removal; the tool electrode is driven by the main shaft of the machine tool to realize feeding movement, and the positive electrode and the negative electrode of the pulse power supply are respectively connected with the workpiece and the tool electrode to provide proper input energy for compound machining; the water-in-oil emulsion is used as the dual-performance working solution for electric spark electrolytic composite forming processing, and in the processing process, the electric spark forming processing and the electrolytic processing coexist, and the controllable adjustment of the electric spark discharging corrosion removal strength and the anode electrochemical dissolution strength can be realized by changing the water content of the water-in-oil emulsion and the concentration of the aqueous electrolyte. When the water content of the water-in-oil emulsion and the concentration of the aqueous electrolyte reach a proper proportion, most of workpiece materials are removed by electric spark discharge, the surface recast layer is removed by electrochemical dissolution, and finally, the electric spark electrolytic composite forming processing of the workpiece with high precision and no recast layer is realized.
The water-in-oil emulsion is formulated as follows: the first step comprises the following steps of: 27 and laurinol polyoxyethylene ether to form a composite emulsifier; secondly, dissolving solid salt particles in deionized water and uniformly mixing to form a salt solution; and thirdly, mixing the following components in mass ratio of 2: (3-8): mixing the salt solution of (1-2), the white mineral oil and the composite emulsifier at normal temperature, and fully stirring to form water-in-oil coarse emulsion; fourthly, placing the crude emulsion in a constant temperature water bath kettle with the temperature of 80 ℃ and continuously stirring for 15 minutes to enable the crude emulsion to be self-emulsified; and finally, naturally cooling the mixed solution at normal temperature to obtain the required water-in-oil emulsion.
Claims (2)
1. An electric spark electrolytic composite forming processing method based on water-in-oil emulsion is characterized in that: immersing a workpiece in the water-in-oil emulsion, respectively connecting the workpiece and a tool electrode to the positive electrode and the negative electrode of a pulse power supply, and driving the tool electrode to realize feeding motion by a machine tool spindle; the water-in-oil emulsion is flushed into the processing area to provide fresh working fluid for the processing gap and assist chip removal; in the machining process, the electric spark forming machining and the electrolytic machining coexist, the workpiece material is etched and removed by utilizing the high temperature generated by the electric spark forming machining, and the recast layer generated by the electric spark machining is removed by utilizing the electrolytic machining; the electric spark forming processing and the controllable adjustment of the electrolytic processing strength are realized through different combinations of the water content of the water-in-oil emulsion and the concentration of the aqueous electrolyte;
The water-in-oil emulsion consists of deionized water, solid salt, white mineral oil and a composite emulsifier; the composite emulsifier comprises the following components in percentage by mass: 27 sorbitan fatty acid ester and laurinol polyoxyethylene ether; the mass ratio of deionized water, white mineral oil and composite emulsifier is 2: (3-8): (1-2); the solid salt is formed by combining one or more salts of NaCl, naNO 3, naClO 3 and the like;
The preparation process of the water-in-oil emulsion is as follows: the first step comprises the following steps of: 27 and laurinol polyoxyethylene ether to form a composite emulsifier; secondly, dissolving solid salt particles in deionized water and uniformly mixing to form a salt solution; and thirdly, mixing the following components in mass ratio of 2: (3-8): the salt solution, the white mineral oil and the composite emulsifier in the step (1-2) are mixed at normal temperature and fully stirred to form water-in-oil coarse emulsion; fourthly, placing the crude emulsion in a constant temperature water bath kettle with the temperature of 80 ℃ and continuously stirring for 15 minutes to enable the crude emulsion to be self-emulsified; and finally, naturally cooling the mixed solution at normal temperature to obtain the required water-in-oil emulsion.
2. The electric spark electrolytic composite forming processing method based on the water-in-oil emulsion according to claim 1, wherein the water-in-oil emulsion is flushed into the processing area in a flushing mode, which can be an inner flushing mode, an outer flushing mode and an inner and outer combined flushing mode.
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| CN202210707395.3A CN115090973B (en) | 2022-06-22 | 2022-06-22 | Electric spark electrolytic composite forming processing method based on water-in-oil emulsion |
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| CN202210707395.3A CN115090973B (en) | 2022-06-22 | 2022-06-22 | Electric spark electrolytic composite forming processing method based on water-in-oil emulsion |
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Citations (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN109365931A (en) * | 2018-12-04 | 2019-02-22 | 中国石油大学(华东) | Sinking EDM water-in-oil type nanometer working solution |
| CN111730156A (en) * | 2020-07-07 | 2020-10-02 | 南京工业大学 | Amplitude-variable pulse electric spark-electrolysis combined machining method |
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| Publication number | Priority date | Publication date | Assignee | Title |
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| GB1368841A (en) * | 1972-03-29 | 1974-10-02 | Polygraph Leipzig | Method of forming metal workpieces by electro-chemical metal disintegration |
| KR101474327B1 (en) * | 2012-11-15 | 2014-12-18 | 서울대학교산학협력단 | Manufacturing apparatus for using spark-assisted machining and manufacturing method thereof |
| CN104923869B (en) * | 2015-04-30 | 2017-07-11 | 南京航空航天大学 | The controllable combined machining method of micro hole vibrating electrode electric spark and electrolysis and vibrational system |
| CN104959684B (en) * | 2015-05-27 | 2017-02-15 | 南京航空航天大学 | Conductivity adjustable atomizing medium electric spark discharge ablation and electrolytic combined machining method |
| CN111618384B (en) * | 2020-06-05 | 2021-08-27 | 南京工业大学 | Threaded pipe electrode matching internal and external flushing electric spark-electrolysis combined hole making method |
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Patent Citations (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN109365931A (en) * | 2018-12-04 | 2019-02-22 | 中国石油大学(华东) | Sinking EDM water-in-oil type nanometer working solution |
| CN111730156A (en) * | 2020-07-07 | 2020-10-02 | 南京工业大学 | Amplitude-variable pulse electric spark-electrolysis combined machining method |
Non-Patent Citations (1)
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