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Advancing electrochemical drilling process via coupling of flow field and electric field in pulsating state generated by a novel tube tool

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Chinese Journal of Aeronautics 2024年第4期37卷 542-555页

作者： Liang CHENG Xiaolei CHEN Zhisen YE Yongjun ZHANG State Key Laboratory of Precision Electronic Manufacturing Technology and Equipment Guangdong University of TechnologyGuangzhou 510006China Guangdong Key Laboratory of Advanced Manufacturing Technology of Marine Energy Equipment Guangdong University of TechnologyGuangzhou 510006China Guangzhou Key Laboratory of Nontraditional Machining and Equipment Guangdong University of TechnologyGuangzhou 510006China

This paper introduces an improvement to electrochemical drilling process by coupling flow field and electric field in pulsating state. A novel tube with half-wedged shape at the end(HW-tube) is prepared, with both sidewall and wedged part of the HW-tube insulated. Only the flat part is utilized to provide electric field for electrochemical drilling. By rotating the HW-tube, both flow field and electric field in pulsating state are generated, alternating in different positions within the inter-electrode gap(IEG). The pulsating flow field enhances the mass transfer process, while pulsating electric field disperses material dissolution process and distribution of electrolytic byproducts. Both pulsating fields are coupled at the same frequency, further enhancing the electrochemical drilling process. Simulation results indicate that both flow field and electric field in pulsating state are generated. Compared to the traditional tube, the HW-tube significantly reduces the number of residual particles in IEG, and this number is further reduced by increasing the rotation speed. Experimental results reveal that the surface quality and dimensional uniformity of small hole are improved with HW-tube. With feed rate of 2.22 mm/min, a small hole with diameter of 1.52± 0.017 mm is drilled, resulting in a surface roughness of 0.331 μm.

关键词： Small holes electrochemical drilling Tools Pulsating flow field Pulsating electric field

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electrochemical drilling of small holes by regulating in real-time the electrolyte flowrate in multiple channels

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Chinese Journal of Aeronautics 2022年第5期35卷 470-483页

作者： Jinxing LUO Xiaolong FANG Tao YANG Di ZHU National Key Laboratory of Science and Technology on Helicopter Transmission Nanjing University of Aeronautics and AstronauticsNanjing 210016China Jiangsu Key Laboratory of Precision and Micro-Manufacturing Technology Nanjing University of Aeronautics and AstronauticsNanjing 210016China

electrochemical drilling(ECD)provides an alternative technique for drilling multiple small holes in difficult-to-machine materials in numerous industrial applications such as for aeroengines.The value and fluctuation of electrolyte flowrate can seriously affect the machining stability and hole quality in ECD.In particular,when drilling multiple holes,the distribution and fluctuations of the electrolyte flowrate in each channel could influence the uniformity of the electrolyte flowrate among multiple tube electrodes,thereby affecting the machining stability and the maximum feed rate.Thus,an eight-channel flow control system was developed to measure and regulate in real time the electrolyte flowrate supplied into each individual tube electrode.This paper proposes ECD of small holes with real-time flowrate control to improve the uniformity of electrolyte flowrate in each tube electrode and reduce the fluctuations in the electrolyte flowrate.In single-hole drilling,when the electrolyte flowrate was regulated in real time,the hole quality and machining stability were considerably better than without regulation.This is because the electrolyte flowrate remains basically constant,which stabilizes the flow field.Moreover,by considering the hole profile,it was found that an electrolyte flowrate of 200.0 m L/min can be acceptable for ECD of small holes.When the eight-channel flow control system was used in multiple-hole drilling,the uniformity of the electrolyte flowrate in each tube electrode was obviously improved,which led to a more stable process.Additionally,the maximum feed rate can attain 2.40 mm/min in multiple-hole drilling.Based on these findings,a matrix(5×32)of multiple small holes was successfully fabricated with a satisfactory diameter consistency,as the machining stability and machining efficiency had been enhanced.

关键词： electrochemical drilling Small holes Electrolyte flowrate Real-time regulation Machining stability

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