Electrolyte vibration electrochemical discharge machining device and method based on force sensing

Abstract

This application relates to the technical field of electrochemical machining and provides a force-sensing-based electrolyte vibration electrochemical discharge machining device and method. The force-sensing-based electrolyte vibration electrochemical discharge machining device includes an electrochemical discharge power supply, an electrode assembly, a spindle assembly, an electrostatic attraction assembly, a clamping assembly, a moving platform, a force-sensing unit, an ultrasonic vibration unit, an electrolyte replacement assembly, a motion controller, a gas supply unit, a marble platform, an air flotation platform, and a control unit. This device can adjust the discharge gap through force-sensing feedback, and by combining electrolyte vibration and cyclic replacement, it achieves the invention objective of high-precision electrochemical discharge machining of difficult-to-machine materials. In addition, this application also provides a method applied to the force-sensing-based electrolyte vibration electrochemical discharge machining device.

Description

Technical Field

[0001] This application relates to the technical field of electrochemical processing, and in particular to an electrolyte vibration electrochemical discharge processing device and method based on force sensing. Background Technology

[0002] Electrochemical electrical discharge machining (EDM) is a composite machining method that combines the advantages of electrochemical machining and electrical discharge machining. It uses high temperature and high pressure generated by pulsed discharge in an electrolyte to etch away materials, playing a crucial role in the precision manufacturing of difficult-to-machine materials such as ceramics, titanium alloys, and nickel-based superalloys. This technology can overcome the bottlenecks of traditional machining for high-hardness and brittle materials, achieving efficient forming of complex structural parts. It has significant application value in high-end manufacturing fields such as aerospace engine blades, precision components for medical devices, and ceramic substrates for electronic packaging.

[0003] Although electrochemical discharge composite technology has made some progress, the inherent characteristics of difficult-to-machine materials, such as high hardness, high brittleness, and poor thermal conductivity, make the material removal mechanism complex during processing. The machined surface is prone to defects such as microcracks and chipping. These defects can lead to stress concentration in the machined parts during service, causing fatigue fracture. For components with high precision requirements, deviations in surface quality and dimensional accuracy will directly affect the overall performance of the components.

[0004] Existing processing solutions cannot simultaneously achieve efficient electrolyte renewal and coordinated control of the discharge process and feed action, resulting in insufficient processing stability. This makes it difficult to continuously and stably guarantee the surface quality, dimensional accuracy, and processing efficiency of the processed parts, and thus cannot meet the high-precision processing requirements of the high-end manufacturing field. Summary of the Invention

[0005] In view of this, this application aims to propose an electrolyte vibration electrochemical discharge processing device and method based on force sensing to solve the above-mentioned technical problems.

[0006] To achieve the above objectives, the technical solution of this application is implemented as follows: In a first aspect, this application proposes an electrolyte vibration electrochemical discharge machining device based on force sensing, comprising: Electrochemical discharge power supply, used to provide stable electrical energy for electrochemical reactions and spark discharges; Electrode assemblies, including tool electrodes and auxiliary electrodes, are used to release electrical energy to process materials; The spindle assembly includes a rotary spindle, a spring collet mounted on the rotary spindle, an air cooling nozzle, and a spindle controller, used to fix and drive the tool electrode to rotate. An electrode assembly for making the tool electrode a reaction cathode; The clamping assembly includes a clamping body, a copper sleeve, and a set screw; the copper sleeve has a notch, with the inner ring engaging with the rotating spindle and the outer ring engaging with the clamping body; the set screw is used to fix the copper sleeve and reduce the size of its notch, thereby clamping the rotating spindle. A mobile platform is used to achieve the relative positional movement of components required during electrochemical discharge machining. Force sensing unit, used to detect macroscopic forces during processing and generate feedback signals; Electrolyte replacement assembly is used to realize the cyclic replacement of substances during electrochemical discharge machining; An ultrasonic vibration unit is used to cause the electrolyte replacement assembly to vibrate; A motion controller is used to control the movement of the mobile platform; The air supply unit includes an air pump, air pipes, an air filter, and a pressure reducing valve; The air pump generates high-pressure air, which enters the air filter through the air pipe for filtration and drying. Then, the air pressure is stabilized by the pressure reducing valve and enters the air cooling nozzle through the air pipe to provide dry air for spindle cooling. A marble stand is used to securely mount the mobile platform. An air-floating platform is used to support the marble platform; The control unit includes a control panel, a data cable, a control cabinet, and a control line. The control panel is electrically connected to the control cabinet via the data cable, and the control cabinet is electrically connected to the electrochemical discharge power supply, spindle assembly, moving platform, force sensing unit, ultrasonic vibration unit, electrolyte replacement assembly, and air pump via the control line, for controlling the operation of the entire processing process.

[0007] Furthermore, the electrochemical discharge power supply includes a signal generator, a power amplifier, an oscilloscope, and wires; The signal generator is used to generate electrical signals of various waveforms, and the processing voltage, waveform, frequency, and duty cycle can be set. The power amplifier is used to adjust voltage parameters, including a positive output terminal and a negative output terminal; The oscilloscope is used to observe the discharge waveform in real time. The wire is used to connect the electrode assembly to realize the transfer of electrical energy.

[0008] Furthermore, the tool electrode is a double-helix hollow coated column electrode with a double-helix groove pitch of 0.5-2mm and a depth of 0.1-0.5mm; The tool electrode sidewall is provided with an alumina coating, the thickness of which is 5-50 μm.

[0009] Furthermore, the auxiliary electrode is electrically connected to the positive output terminal of the power amplifier via the wire, serving as the reaction anode; The auxiliary electrode and the tool electrode form a current loop, where a hydrogen evolution reaction occurs, balancing the electrochemical system.

[0010] Furthermore, the power-feeding assembly includes a nylon bracket, a bearing, a fastening screw, an adjusting spring, and an adjusting screw; The nylon bracket is connected to the clamping assembly via an adjusting spring and an adjusting screw, so that the current-leading assembly and the clamping assembly maintain a relative positional margin. The inner ring of the bearing is fixedly connected to the spring collet, and the outer ring is connected to the nylon bracket by the fastening screw; One end of the wire is electrically connected to the fastening screw, and the other end is electrically connected to the negative output terminal of the power amplifier, so that the spring collet is electrically connected to the negative output terminal of the power amplifier, and the tool electrode serves as the reaction cathode.

[0011] Furthermore, the force sensing unit includes a pressure sensor, a base plate, an analog signal amplifier, and an output line; The pressure sensor is fixedly connected to the base plate, and the base plate is fixedly connected to the moving platform, for measuring the macroscopic force during the processing. The signal generated by the pressure sensor is electrically connected to the analog signal amplifier through the output line, which can send the detected analog signal to the control unit. The motion controller controls the moving platform and adjusts the size of the discharge gap in real time.

[0012] Furthermore, the ultrasonic vibration unit includes an ultrasonic generator, an ultrasonic transducer, a signal line, a base plate, and a top plate; The ultrasonic generator is used to generate high-frequency vibration electrical signals. The ultrasonic transducer is electrically connected to the ultrasonic generator via the signal line, and is used to convert the vibration electrical signal into a mechanical vibration signal. The bottom end of the ultrasonic transducer is connected to the base plate, and the top end is connected to the top plate; the base plate has a circular hole and is connected to the pressure sensor; the top plate is fixedly connected to the electrolyte replacement assembly and is used to drive the electrolyte replacement assembly to vibrate.

[0013] Furthermore, the electrolyte replacement assembly includes an electrolytic cell, an electrolyte, a high-pressure pump, a plastic tube, a storage tank, a waste tank, and a sample stage; The electrolytic cell is used to hold the electrolyte and serves as an electrochemical discharge processing site, with round holes at both ends of the sidewall. The electrolyte is a mixed electrolyte of KOH and NaOH, with a mass ratio of 1:1 to 3:1 and a concentration of 5% to 20%. The high-pressure pump is used to drive the circulation and replacement of the electrolyte. The inlet is connected to the storage tank through the plastic tube, and the outlet is connected to a round hole on one side of the electrolytic cell through the plastic tube. The processed waste liquid enters the waste liquid tank through the plastic tube via a round hole on the other side of the electrolytic cell. The sample stage is used to fix the workpiece to be processed.

[0014] Furthermore, the mobile platform includes a Z-axis mobile platform, an X-axis mobile platform, a Y-axis mobile platform, a first adapter plate, a second adapter plate, and a third adapter plate; The Z-axis moving platform is fixed to the clamping assembly via the first adapter plate, which enables the vertical movement of the spindle assembly; the X-axis moving platform is connected to the Y-axis moving platform via the second adapter plate, with the X-axis moving platform above the Y-axis moving platform; the Y-axis moving platform is fixed to the marble frame via the third adapter plate. The marble platform includes a gantry and a water platform. The gantry fixes the Z-axis moving platform, and the water platform fixes the Y-axis moving platform.

[0015] Secondly, this application proposes a method for use in the aforementioned force-sensing-based electrolyte vibration electrochemical discharge machining apparatus, comprising the following steps: Step 1: Select the tool electrode with appropriate parameters according to the processing requirements, and fix it to the rotating spindle by the spring collet; Step 2: Prepare a mixture of KOH and NaOH, set the ratio of the mixture according to the processing requirements, and pour it into the storage tank; Step 3: Fix the workpiece to be processed on the sample stage, control the moving platform through the control unit, adjust the relative position of the workpiece and the tool electrode to ensure the processing area is aligned, and set the workpiece coordinate system; Step 4: Control the signal generator through the control unit, set the processing voltage, waveform, frequency and duty cycle according to the processing requirements, adjust the power amplifier to make the output voltage and frequency reach the set values, and observe whether the discharge waveform is stable through the oscilloscope; Step 5: Control the ultrasonic generator through the control unit, and set the amplitude of the ultrasonic transducer according to the processing requirements to make the electrolyte vibrate; Step 6: Control the spindle assembly through the control unit, and set the spindle speed according to the processing requirements; Step 7: Write a machining program through the control unit to control the moving platform, so that the tool electrode rotates and feeds towards the workpiece. The machining program coordinates the discharge, vibration and feeding actions. Step 8: Control the electrolyte replacement assembly through the control unit and set the flow rate of the high-pressure pump; Step 9: The processing program is executed through the control unit to begin electrochemical discharge processing; Step 10: After processing is completed, the control unit sequentially shuts down the rotary spindle, ultrasonic generator, signal generator, and electrolyte replacement assembly; Step 11: Control the spindle controller through the control unit to move the tool electrode away from the workpiece and remove the machined workpiece; Step 12: Turn off the power and clean the processing device.

[0016] Compared with existing technologies, the electrolyte vibration electrochemical discharge machining device and method based on force sensing proposed in this application have the following advantages: (1) This application detects the macroscopic force of the processing process by force sensing unit and generates feedback signal, which is used in conjunction with control unit and motion controller to control the movement of the moving platform. Combined with electrochemical discharge power supply to provide stable processing power, the electrode assembly is stably conductive and reliably fixed by the electric lead assembly and clamping assembly. Real-time control of the discharge gap during processing is realized, ensuring the effect of coordinated matching between discharge energy and feed action during processing.

[0017] (2) This application uses an ultrasonic vibration unit to drive the electrolyte replacement component to generate vibration, and works with the electrolyte replacement component to realize the circulation replacement of electrolyte during the processing. Combined with the structural design of the tool electrode, the electrolyte flow field in the processing area is optimized, which realizes the efficient renewal of electrolyte in the processing area, timely discharge of the erosion products generated during processing, avoids secondary discharge, and ensures the integrity of the processing surface.

[0018] (3) This application drives the tool electrode to rotate through the spindle assembly, and achieves stable cooling of the spindle in conjunction with the air supply unit. The overall installation stability of the device is ensured by the marble stand and the air flotation platform. Combined with the matching processing method, the operation of each component is coordinated, thus realizing stable and continuous operation of the processing process and improving the dimensional accuracy and processing efficiency of difficult-to-machine materials. Attached Figure Description

[0019] The accompanying drawings, which form part of this application, are used to provide a further understanding of this application. The illustrative embodiments and descriptions of this application are used to explain this application and do not constitute an undue limitation of this application. In the drawings: Figure 1 This is a schematic diagram of the structure of the electrolyte vibration electrochemical discharge machining device based on force sensing described in the embodiments of this application; Figure 2 This is a schematic diagram of the structure of the force sensing unit, ultrasonic vibration unit, and electrolyte replacement assembly described in the embodiments of this application; Figure 3 This is a schematic diagram of the spindle assembly, power supply assembly, and clamping assembly described in the embodiments of this application.

[0020] Explanation of reference numerals in the attached figures: 1. Electrochemical discharge power supply; 101. Signal generator; 102. Power amplifier; 103. Oscilloscope; 104. Wires; 2. Electrode assembly; 201. Tool electrode; 202. Auxiliary electrode; 3. Spindle assembly; 301. Rotary spindle; 302. Spring collet; 303. Air cooling nozzle; 304. Spindle controller; 4. Current-leading assembly; 401. Nylon bracket; 402. Bearing; 403. Fastening screw; 404. Adjusting spring; 405. Adjusting screw; 5. Clamping assembly; 501. Clamping body; 502. Copper sleeve; 503. Set screw; 6. Moving platform; 601. Z-axis moving platform; 602. X-axis moving platform; 603. Y-axis moving platform; 7. Shaft Moving Platform; 604. First Adapter Plate; 605. Second Adapter Plate; 606. Third Adapter Plate; 7. Force Sensing Unit; 701. Pressure Sensor; 702. Base Plate; 703. Analog Signal Amplifier; 704. Output Line; 8. Ultrasonic Vibration Unit; 801. Ultrasonic Generator; 802. Ultrasonic Transducer; 803. Signal Line; 804. Base Plate; 805. Top Plate; 9. Electrolyte Replacement Assembly; 901. Electrolyte Cell; 902. Electrolyte; 903. High Voltage Pump; 904, Plastic tubing; 905, Liquid storage tank; 906, Waste liquid tank; 907, Sample stage; 10, Motion controller; 11, Air supply unit; 1101, Air pump; 1102, Air pipe; 1103, Air filter; 1104, Pressure reducing valve; 12, Marble platform; 1201, Gantry; 1202, Water platform; 13, Air flotation platform; 14, Control unit; 1401, Control panel; 1402, Data cable; 1403, Control cabinet; 1404, Control cable. Detailed Implementation

[0021] To make the technical solution and advantages of this application clearer, the following detailed description is provided in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the scope of this application.

[0022] It should be noted that, unless otherwise specified, the embodiments and features described in this application can be combined with each other.

[0023] Furthermore, it should be noted that in the description of this application, if terms such as "upper," "lower," "inner," or "outer" appear, indicating orientation or positional relationship, these are based on the orientation or positional relationship shown in the accompanying drawings and are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation on this application. In addition, if terms such as "first" or "second" appear, they are also used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0024] Furthermore, in the description of this application, unless otherwise expressly defined, the terms "installation," "connection," "joining," and "connector" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection between two components. Those skilled in the art can understand the specific meaning of the above terms in this application in light of the specific circumstances.

[0025] In this application, the terms "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., refer to a specific feature, structure, material, or characteristic described in connection with that embodiment or example, which is included in at least one embodiment or example of this application. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0026] The present application will now be described in detail through exemplary embodiments. However, it should be understood that, without further description, elements, structures, and features in one embodiment may be advantageously incorporated into other embodiments.

[0027] Example 1 The force-sensing-based electrolyte vibration electrochemical discharge machining apparatus disclosed in this application can be applied to the precision machining of high-hardness, high-brittleness, and difficult-to-machine materials. The solution described in this application will be described in detail below.

[0028] Reference Figures 1 to 3 The force-sensing electrolyte vibration electrochemical discharge processing device according to the present application includes an electrochemical discharge power supply 1, an electrode assembly 2, a spindle assembly 3, an electric current drawing assembly 4, a clamping assembly 5, a moving platform 6, a force sensing unit 7, an ultrasonic vibration unit 8, an electrolyte replacement assembly 9, a motion controller 10, an air supply unit 11, a marble platform 12, an air flotation platform 13, and a control unit 14.

[0029] Electrochemical discharge power supply 1 is used to provide stable electrical energy for electrochemical reactions and spark discharges, providing an energy source for the entire processing.

[0030] Electrode assembly 2 includes a tool electrode 201 and an auxiliary electrode 202, which are used to release electrical energy to complete the processing of materials. It is the core component for energy release and electrochemical reaction during the processing.

[0031] The spindle assembly 3 includes a rotary spindle 301, a spring collet 302 mounted on the rotary spindle 301, an air cooling nozzle 303, and a spindle controller 304, used to fix and drive the tool electrode 201 to rotate. The spring collet 302 is used to clamp and fix the tool electrode 201, the spindle controller 304 is used to control the speed and start / stop of the rotary spindle 301, and the air cooling nozzle 303 is used to provide cooling medium to the rotary spindle 301 to ensure stable operation of the spindle over a long period of time.

[0032] The current-inducing assembly 4 is used to make the tool electrode 201 a reaction cathode, thereby achieving stable conduction of the processing circuit.

[0033] The clamping assembly 5 includes a clamping body 501, a copper sleeve 502, and a set screw 503. The copper sleeve 502 has a notch, with its inner ring engaging with the rotating spindle 301 and its outer ring engaging with the clamping body 501. The set screw 503 is used to fix the copper sleeve 502 and reduce the size of its notch, thereby clamping the rotating spindle 301 and achieving stable clamping and fixing of the spindle assembly 3.

[0034] The mobile platform 6 is used to realize the relative position movement of the components required during the electrochemical discharge machining process, providing precise position adjustment and feed action for the machining process.

[0035] The force sensing unit 7 is used to detect the macroscopic forces acting during the processing and generate feedback signals, providing data for real-time control of the processing.

[0036] The electrolyte replacement assembly 9 is used to realize the cyclic replacement of substances during electrochemical discharge machining, ensuring the stability of the electrolyte state in the machining area. The ultrasonic vibration unit 8 is used to generate vibration in the electrolyte replacement assembly 9, optimizing the electrolyte flow field state in the machining area.

[0037] The motion controller 10 is used to control the movement of the mobile platform 6, thereby achieving precise motion control of the mobile platform 6.

[0038] The air supply unit 11 includes an air pump 1101, an air pipe 1102, an air filter 1103, and a pressure reducing valve 1104. The air pump 1101 generates high-pressure air, which enters the air filter 1103 through the air pipe 1102 for filtration and drying. Then, it passes through the pressure reducing valve 1104 to stabilize the air pressure before entering the air cooling nozzle 303 through the air pipe 1102 to provide dry air for spindle cooling. The air supply unit 11 provides a stable source of dry air for cooling the rotating spindle 301, preventing temperature rise caused by prolonged spindle operation from affecting machining accuracy.

[0039] The marble frame 12 is used to fix and install the mobile platform 6, providing a high-rigidity and high-stability mounting base for the moving parts of the device. The air-floating platform 13 is used to support the marble frame 12, isolate external vibrations from interfering with the processing process, and ensure the stability of the processing process.

[0040] The control unit 14 includes a control panel 1401, a data cable 1402, a control cabinet 1403, and a control cable 1404. The control panel 1401 is electrically connected to the control cabinet 1403 via the data cable 1402. The control cabinet 1403 is electrically connected to the electrochemical discharge power supply 1, the spindle assembly 3, the moving platform 6, the force sensing unit 7, the ultrasonic vibration unit 8, the electrolyte replacement assembly 9, and the air pump 1101 via the control cable 1404, and is used to control the operation of the entire processing process. The control unit 14, as the control core of the device, realizes the coordinated operation and parameter adjustment of various components.

[0041] Through the above overall structure, this application constructs a complete electrochemical discharge machining system, which integrates force sensing feedback, ultrasonic vibration assistance, electrolyte circulation and replacement, and machining feed control, providing a hardware foundation for the stable operation of the machining process. It enables the coordinated cooperation of various functional modules, solves the problem of poor matching of various links in existing machining devices, and ensures the stability and controllability of the machining process.

[0042] Reference Figure 1 The electrochemical discharge power supply 1 includes a signal generator 101, a power amplifier 102, an oscilloscope 103, and connecting wires 104. The signal generator 101 generates electrical signals of various waveforms and allows setting the processing voltage, waveform, frequency, and duty cycle. The power amplifier 102 adjusts voltage parameters, including the positive and negative output terminals. The oscilloscope 103 is used to observe the discharge waveform in real time. The connecting wires 104 connect to the electrode assembly 2 to transfer electrical energy. The signal generator can provide DC and AC signals in the form of sine waves, square waves, and pulses, with a voltage adjustment range of 20-300V and a frequency of 1-50kHz. The power amplifier's amplification factor is adjustable from 0.1-100 to ensure stable output signals. The oscilloscope has a sampling frequency of at least 100MHz, enabling clear observation of the dynamic changes in the discharge waveform.

[0043] By using a signal generator to flexibly control the processing electrical signal, and working with a power amplifier to ensure stable output power, and then using an oscilloscope to monitor the discharge waveform in real time, operators can keep track of the discharge status during the processing, ensuring a stable and controllable power supply during the processing, avoiding the impact of electrical parameter fluctuations on processing quality, and providing a reliable energy supply for stable electrochemical discharge processing.

[0044] Reference Figure 1 The tool electrode 201 is a double-helix hollow coated column electrode with a double-helix groove pitch of 0.5-2 mm and a depth of 0.1-0.5 mm. The sidewalls of the tool electrode 201 are coated with an alumina coating with a thickness of 5-50 μm. The double-helix grooves can be fabricated using a dual-wire discharge electrical discharge machining (DED) process, and the alumina coating can be deposited using a plasma electrolytic oxidation process.

[0045] The double helix structure can drive the electrolyte to form a directional flow during electrode rotation, improving the electrolyte renewal efficiency in the processing area. Combined with the alumina coating on the sidewall, it can improve the corrosion resistance of the tool electrode, reduce electrode wear during processing, extend electrode life, and at the same time ensure the stability of the discharge area during processing, thus improving the dimensional accuracy of processing.

[0046] The auxiliary electrode 202 is electrically connected to the positive output terminal of the power amplifier 102 via a wire 104, serving as the reaction anode. The auxiliary electrode 202 and the tool electrode 201 form a current loop, initiating a hydrogen evolution reaction to balance the electrochemical system. The auxiliary electrode 202 can be made of graphite sheet, with dimensions of 50×50×5mm.

[0047] By using an auxiliary electrode as the anode and a tool electrode as the cathode to form a complete current loop, the system balance during electrochemical processing can be stabilized, ensuring the stable occurrence of the hydrogen evolution reaction and providing a basis for the formation of a gas film and stable discharge. The larger area of ​​the auxiliary electrode can maintain the relative stability of the electrolyte concentration, further improving the operational stability of the electrochemical system.

[0048] Reference Figure 1 and Figure 2The current-leading assembly 4 includes a nylon bracket 401, a bearing 402, a fastening screw 403, an adjusting spring 404, and an adjusting screw 405. The nylon bracket 401 is connected to the clamping assembly 5 via the adjusting spring 404 and the adjusting screw 405, maintaining a relative positional margin between the current-leading assembly 4 and the clamping assembly 5. The inner ring of the bearing 402 is fixedly connected to the spring collet 302, and the outer ring is connected to the nylon bracket 401 via the fastening screw 403. One end of the wire 104 is electrically connected to the fastening screw 403, and the other end is electrically connected to the negative output terminal of the power amplifier 102, thus electrically connecting the spring collet 302 to the negative output terminal of the power amplifier 102, making the tool electrode 201 the reaction cathode. The bearing 402 is enclosed, made of silver-graphite composite material, with a conductivity of not less than 95% and a wear rate of not more than 0.005 mm / h.

[0049] Stable current conduction during rotation is achieved through a bearing structure, preventing wire entanglement as the spindle rotates. The nylon bracket ensures insulation between the current conduction assembly and other components. The combination of the adjusting spring and adjusting screw buffers vibrations generated during spindle operation, preventing vibrations from affecting current conduction stability. The high conductivity and low wear rate of the bearing material ensures stable current transmission and extends the service life of the current conduction assembly.

[0050] Reference Figure 1 and Figure 3 The force sensing unit 7 includes a pressure sensor 701, a base plate 702, an analog signal amplifier 703, and an output line 704. The pressure sensor 701 is fixedly connected to the base plate 702, which in turn is fixedly connected to the moving platform 6. It is used to measure the macroscopic forces acting during the machining process. The signal generated by the pressure sensor 701 is electrically connected to the analog signal amplifier 703 via the output line 704. This allows the detected analog signal to be sent to the control unit 14, which in turn controls the moving platform 6 via the motion controller 10, adjusting the discharge gap size in real time. The pressure sensor 701 has a range of 0-50N, is made of stainless steel, and consists of four sensors arranged in a 2×2 configuration.

[0051] By using a pressure sensor to detect the macroscopic forces during the machining process in real time, the relative state between the tool electrode and the workpiece can be directly reflected. The signal, amplified by an analog signal amplifier, is transmitted to the control unit, enabling real-time adjustment of the machining feed action. This allows for precise control of the discharge gap, ensuring the coordinated matching of discharge energy and feed action during machining. It avoids problems such as the inability to form a stable discharge due to an excessively large gap, or mechanical collision damage to the workpiece and electrode due to an excessively small gap, thereby improving the stability and accuracy of the machining process.

[0052] Reference Figure 1 and Figure 3The ultrasonic vibration unit 8 includes an ultrasonic generator 801, an ultrasonic transducer 802, a signal line 803, a base plate 804, and a top plate 805. The ultrasonic generator 801 generates high-frequency vibration electrical signals. The ultrasonic transducer 802 is electrically connected to the ultrasonic generator 801 via the signal line 803, converting the vibration electrical signals into mechanical vibration signals. The bottom end of the ultrasonic transducer 802 is connected to the base plate 804, and the top end is connected to the top plate 805. The base plate 804 has a circular hole and is connected to a pressure sensor 701. The top plate 805 is fixedly connected to the electrolyte replacement assembly 9, driving the electrolyte replacement assembly 9 to vibrate. The ultrasonic generator 801 operates at a frequency of 20-50 kHz, the ultrasonic transducer 802 has an amplitude adjustment range of 5-50 μm, and there are six ultrasonic transducers 802 arranged in a 3×2 configuration.

[0053] The ultrasonic generator and transducer convert electrical signals into mechanical vibrations, which drive the electrolyte replacement component to generate high-frequency vibrations. This causes the electrolyte in the processing area to fluctuate at high frequencies, breaking up localized gas film build-up during processing and making the gas film distribution more uniform. At the same time, the cavitation effect generated by the vibration promotes the removal of erosion products from the processing area. Combined with the circulation of the electrolyte, this further improves the cleanliness of the processing area, avoids secondary discharge, and ensures the integrity of the processed surface.

[0054] Reference Figure 1 and Figure 3 The electrolyte replacement assembly 9 includes an electrolytic cell 901, an electrolyte 902, a high-pressure pump 903, a plastic tube 904, a storage tank 905, a waste liquid tank 906, and a sample stage 907. The electrolytic cell 901 holds the electrolyte 902 and serves as the electrochemical discharge processing area; it has circular holes at both ends of its sidewall. The electrolyte 902 is a mixed electrolyte of KOH and NaOH with a mass ratio of 1:1-3:1 and a concentration of 5%-20%. The high-pressure pump 903 drives the circulation and replacement of the electrolyte 902. Its inlet is connected to the storage tank 905 via a plastic tube 904, and its outlet is connected to one of the circular holes on one side of the electrolytic cell 901 via a plastic tube 904. The processed waste liquid enters the waste liquid tank 906 through the other circular hole on the electrolytic cell 901 and through the plastic tube 904. The sample stage 907 is used to fix the workpiece to be processed. The 903 high-pressure pump can provide a delivery pressure of 0.3-1.5MPa, and the matching filter has an accuracy of no more than 5μm.

[0055] By driving the electrolyte through a high-pressure pump to form a continuous circulation between the storage tank, the electrolytic tank, and the waste tank, the electrolyte in the processing area can be continuously renewed. This promptly removes the erosion products and heat generated during processing, ensuring the stability of the electrolyte concentration and temperature in the processing area. It also prevents the processing condition from deteriorating due to electrolyte stagnation. The mixed electrolyte can ensure the stable occurrence of electrochemical reactions, providing a good electrolyte environment for stable discharge, thereby improving the consistency and quality of the processing.

[0056] Reference Figure 1 The moving platform 6 includes a Z-axis moving platform 601, an X-axis moving platform 602, a Y-axis moving platform 603, a first adapter plate 604, a second adapter plate 605, and a third adapter plate 606. The Z-axis moving platform 601 is fixed to the clamping assembly 5 via the first adapter plate 604, enabling vertical movement of the spindle assembly 3. The X-axis moving platform 602 is connected to the Y-axis moving platform 603 via the second adapter plate 605, with the X-axis moving platform 602 positioned above the Y-axis moving platform 603. The Y-axis moving platform 603 is fixed to the marble frame 12 via the third adapter plate 606. The marble frame 12 includes a gantry 1201 and a water platform 1202. The gantry 1201 fixes the Z-axis moving platform 601, and the water platform 1202 fixes the Y-axis moving platform 603.

[0057] By setting up a three-axis moving platform, it is possible to achieve precise multi-degree-of-freedom position adjustment and feed motion between the tool electrode and the workpiece, meeting the processing needs of different structures. The marble table has the characteristics of high rigidity and low deformation, which can provide a stable installation foundation for the moving platform and avoid deformation during the movement from affecting the processing accuracy. The gantry-style structural layout can improve the stability of the Z-axis movement and further ensure the accuracy of the processing feed.

[0058] Example 2 This application also provides an electrolyte vibration electrochemical discharge machining method based on force sensing, referring to... Figures 1 to 3 The method, applied to the aforementioned force-sensing-based electrolyte vibration electrochemical discharge machining apparatus, includes the following steps: Step 1: Select a tool electrode 201 with appropriate parameters according to the processing requirements, and fix it to the rotating spindle 301 by spring collet 302.

[0059] Step 2: Prepare a mixture of KOH and NaOH. Set the ratio of the mixture according to the processing requirements and pour it into the storage tank 905.

[0060] Step 3: Fix the workpiece to be processed on the sample stage 907, control the moving platform 6 through the control unit 14, adjust the relative position of the workpiece and the tool electrode 201 to ensure that the processing area is aligned, and set the workpiece coordinate system.

[0061] Step 4: Control the signal generator 101 through the control unit 14, set the processing voltage, waveform, frequency and duty cycle according to the processing requirements, adjust the power amplifier 102 to make the output voltage and frequency reach the set values, and observe whether the discharge waveform is stable through the oscilloscope 103.

[0062] Step 5: Control the ultrasonic generator 801 through the control unit 14, and set the amplitude of the ultrasonic transducer 802 according to the processing requirements to make the electrolyte 902 vibrate.

[0063] Step 6: Control the spindle assembly 3 through the control unit 14 and set the rotation speed of the rotary spindle 301 according to the processing requirements.

[0064] Step 7: The machining program is written through the control unit 14 to control the moving platform 6, so that the tool electrode 201 rotates and feeds towards the workpiece. The machining program coordinates the discharge, vibration and feeding actions.

[0065] Step 8: Control the electrolyte replacement assembly 9 through the control unit 14 and set the flow rate of the high-pressure pump 903.

[0066] Step 9: The machining program is executed by the control unit 14 to begin electrochemical discharge machining.

[0067] After processing is completed in step 10, the rotary spindle 301, ultrasonic generator 801, signal generator 101 and electrolyte replacement assembly 9 are shut down in sequence by the control unit 14.

[0068] Step 11: Control the spindle controller 304 through the control unit 14 to move the tool electrode 201 away from the workpiece and remove the machined workpiece.

[0069] Step 12: Turn off the power and clean the processing device.

[0070] Through the above operation steps, the sequential coordination of each stage of the processing can be achieved. The parameter setting and position adjustment before processing can ensure that the initial processing state is controllable. During processing, the real-time feedback of the force sensing unit, combined with the coordinated operation of each component, can realize the real-time control of the processing state. The orderly shutdown and cleaning after processing can ensure the service life of the device. The entire processing process can stably achieve high-precision and high-efficiency processing of difficult-to-machine materials, and ensure the surface quality and dimensional accuracy of the processed parts.

[0071] The above descriptions are merely some embodiments of this application and are not intended to limit this application. The technical features or structures in the foregoing different embodiments can be arbitrarily combined to form other specific technical solutions as needed. For those skilled in the art, this application can have various modifications and variations. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this application should be included within the scope of protection of the claims of this application.

Claims

1. A force-sensing-based electrolyte vibration electrochemical discharge machining device, characterized in that, include: An electrochemical discharge power supply (1) is used to provide stable electrical energy for electrochemical reactions and spark discharges; The electrode assembly (2) includes a tool electrode (201) and an auxiliary electrode (202) for releasing electrical energy to complete the processing of materials; The spindle assembly (3) includes a rotary spindle (301), a spring collet (302) disposed on the rotary spindle (301), an air cooling nozzle (303), and a spindle controller (304) for fixing and driving the tool electrode (201) to rotate. The current-inducing assembly (4) is used to make the tool electrode (201) a reaction cathode; The clamping assembly (5) includes a clamping body (501), a copper sleeve (502), and a set screw (503); the copper sleeve (502) has a notch, the inner ring of which engages with the rotating spindle (301), and the outer ring of which engages with the clamping body (501); the set screw (503) is used to fix the copper sleeve (502) and reduce the size of its notch, thereby clamping the rotating spindle (301). The mobile platform (6) is used to realize the relative position movement of the components required during the electrochemical discharge machining process; Force sensing unit (7) is used to detect macroscopic forces during the processing and generate feedback signals; Electrolyte replacement assembly (9) is used to realize the cyclic replacement of substances during electrochemical discharge processing; An ultrasonic vibration unit (8) is used to cause the electrolyte replacement assembly (9) to vibrate; Motion controller (10) is used to control the movement of the mobile platform (6); The air supply unit (11) includes an air pump (1101), an air pipe (1102), an air filter (1103), and a pressure reducing valve (1104). The air pump (1101) generates high-pressure air, which enters the air filter (1103) through the air pipe (1102) for filtration and drying. Then, the air pressure is stabilized by the pressure reducing valve (1104) and enters the air cooling nozzle (303) through the air pipe (1102) to provide dry air and achieve spindle cooling. Marble stand (12) is used to fix the mobile platform (6) in place. An air-floating platform (13) is used to support the marble platform (12). The control unit (14) includes a control panel (1401), a data cable (1402), a control cabinet (1403), and a control line (1404). The control panel (1401) is electrically connected to the control cabinet (1403) via the data cable (1402). The control cabinet (1403) is electrically connected to the electrochemical discharge power supply (1), the spindle assembly (3), the moving platform (6), the force sensing unit (7), the ultrasonic vibration unit (8), the electrolyte replacement assembly (9), and the air pump (1101) via the control line (1404) to control the operation of the entire processing process.

2. The electrolyte vibration electrochemical discharge machining device based on force sensing according to claim 1, characterized in that, The electrochemical discharge power supply (1) includes a signal generator (101), a power amplifier (102), an oscilloscope (103), and wires (104). The signal generator (101) is used to generate electrical signals with various waveforms, and the processing voltage, waveform, frequency, and duty cycle can be set. The power amplifier (102) is used to adjust voltage parameters, including a positive output terminal and a negative output terminal; The oscilloscope (103) is used to observe the discharge waveform in real time; The wire (104) is used to connect the electrode assembly (2) to realize the transfer of electrical energy.

3. The electrolyte vibration electrochemical discharge machining device based on force sensing according to claim 1, characterized in that, The tool electrode (201) is a double-helix hollow coated column electrode with a double-helix groove pitch of 0.5-2mm and a depth of 0.1-0.5mm; The tool electrode (201) has an aluminum oxide coating on its sidewall, and the aluminum oxide coating has a thickness of 5-50 μm.

4. The electrolyte vibration electrochemical discharge machining device based on force sensing according to claim 2, characterized in that, The auxiliary electrode (202) is electrically connected to the positive output terminal of the power amplifier (102) via the wire (104) to serve as the reaction anode; The auxiliary electrode (202) and the tool electrode (201) form a current loop, and a hydrogen evolution reaction occurs to balance the electrochemical system.

5. The electrolyte vibration electrochemical discharge machining device based on force sensing according to claim 2, characterized in that, The power supply assembly (4) includes a nylon bracket (401), a bearing (402), a fastening screw (403), an adjusting spring (404), and an adjusting screw (405). The nylon bracket (401) is connected to the clamping assembly (5) via an adjusting spring (404) and an adjusting screw (405) to maintain a relative positional margin between the power supply assembly (4) and the clamping assembly (5); The inner ring of the bearing (402) is fixedly connected to the spring collet (302), and the outer ring is connected to the nylon bracket (401) by the fastening screw (403); One end of the wire (104) is electrically connected to the fastening screw (403), and the other end is electrically connected to the negative output terminal of the power amplifier (102), so that the spring collet (302) is electrically connected to the negative output terminal of the power amplifier (102), and the tool electrode (201) serves as the reaction cathode.

6. The electrolyte vibration electrochemical discharge machining device based on force sensing according to claim 1, characterized in that, The force sensing unit (7) includes a pressure sensor (701), a base plate (702), an analog signal amplifier (703), and an output line (704). The pressure sensor (701) is fixedly connected to the base plate (702), and the base plate (702) is fixedly connected to the moving platform (6), for measuring the macroscopic force during the processing; The signal generated by the pressure sensor (701) is electrically connected to the analog signal amplifier (703) through the output line (704), and the detected analog signal can be sent to the control unit (14), which controls the moving platform (6) through the motion controller (10) to adjust the size of the discharge gap in real time.

7. The electrolyte vibration electrochemical discharge machining apparatus based on force sensing according to claim 6, characterized in that, The ultrasonic vibration unit (8) includes an ultrasonic generator (801), an ultrasonic transducer (802), a signal line (803), a base plate (804), and a top plate (805). The ultrasonic generator (801) is used to generate high-frequency vibration electrical signals; The ultrasonic transducer (802) is electrically connected to the ultrasonic generator (801) via the signal line (803) and is used to convert the vibration electrical signal into a mechanical vibration signal. The bottom end of the ultrasonic transducer (802) is connected to the base plate (804), and the top end is connected to the top plate (805). The base plate (804) has a round hole and is connected to the pressure sensor (701). The top plate (805) is fixedly connected to the electrolyte replacement assembly (9) and is used to drive the electrolyte replacement assembly (9) to vibrate.

8. The electrolyte vibration electrochemical discharge machining device based on force sensing according to claim 1, characterized in that, The electrolyte replacement assembly (9) includes an electrolytic cell (901), an electrolyte (902), a high-pressure pump (903), a plastic tube (904), a storage tank (905), a waste tank (906), and a sample stage (907). The electrolytic cell (901) is used to hold the electrolyte (902) and serves as an electrochemical discharge processing site. Circular holes are provided at both ends of the side wall. The electrolyte (902) is a mixed electrolyte of KOH and NaOH with a mass ratio of 1:1-3:1 and a concentration of 5%-20%. The high-pressure pump (903) is used to drive the circulation and replacement of the electrolyte (902). The inlet is connected to the storage tank (905) through the plastic pipe (904), and the outlet is connected to a round hole on one side of the electrolytic cell (901) through the plastic pipe (904). The processed waste liquid enters the waste liquid tank (906) through the plastic tube (904) via the round hole on the other side of the electrolytic cell (901). The sample stage (907) is used to fix the workpiece to be processed.

9. The electrolyte vibration electrochemical discharge machining device based on force sensing according to claim 1, characterized in that, The mobile platform (6) includes a Z-axis mobile platform (601), an X-axis mobile platform (602), a Y-axis mobile platform (603), a first adapter plate (604), a second adapter plate (605), and a third adapter plate (606). The Z-axis moving platform (601) is fixed to the clamping assembly (5) via the first adapter plate (604) to realize the vertical movement of the spindle assembly (3); the X-axis moving platform (602) and the Y-axis moving platform (603) are connected via the second adapter plate (605), and the X-axis moving platform (602) is above the Y-axis moving platform (603); the Y-axis moving platform (603) is fixed to the marble frame (12) via the third adapter plate (606); The marble platform (12) includes a gantry (1201) and a water platform (1202). The gantry (1201) fixes the Z-axis moving platform (601), and the water platform (1202) fixes the Y-axis moving platform (603).

10. A force-sensing-based electrolyte vibration electrochemical discharge machining method, applied to the force-sensing-based electrolyte vibration electrochemical discharge machining apparatus as described in any one of claims 1 to 9, characterized in that, Includes the following steps: Step 1: Select the tool electrode (201) with appropriate parameters according to the processing requirements, and fix it to the rotating spindle (301) by the spring collet (302). Step 2: Prepare a mixture of KOH and NaOH. Set the ratio of the mixture according to the processing requirements and pour it into the storage tank (905). Step 3: Fix the workpiece to be processed on the sample stage (907), control the moving platform (6) through the control unit (14), adjust the relative position of the workpiece and the tool electrode (201) to ensure that the processing area is aligned, and set the workpiece coordinate system; Step 4: Control the signal generator (101) through the control unit (14), set the processing voltage, waveform, frequency and duty cycle according to the processing requirements, adjust the power amplifier (102) to make the output voltage and frequency reach the set values, and observe whether the discharge waveform is stable through the oscilloscope (103). Step 5: Control the ultrasonic generator (801) through the control unit (14), and set the amplitude of the ultrasonic transducer (802) according to the processing requirements to make the electrolyte (902) vibrate; Step 6: Control the spindle assembly (3) through the control unit (14) and set the rotation speed of the rotary spindle (301) according to the processing requirements; Step 7: The machining program is written through the control unit (14) to control the moving platform (6), so that the tool electrode (201) rotates and feeds to the workpiece. The machining program coordinates the discharge, vibration and feeding actions. Step 8: Control the electrolyte replacement assembly (9) through the control unit (14) and set the flow rate of the high-pressure pump (903); Step 9: The processing program is executed through the control unit (14) to begin electrochemical discharge processing; Step 10: After processing is completed, the control unit (14) sequentially shuts down the rotating spindle (301), ultrasonic generator (801), signal generator (101) and electrolyte replacement assembly (9). Step 11: Control the spindle controller (304) through the control unit (14) to move the tool electrode (201) away from the workpiece and remove the processed workpiece; Step 12: Turn off the power and clean the processing device.

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