Ultrasonic vibration self-adaptive precise electrochemical machining device and method for flexible medium

Abstract

This invention discloses an ultrasonic vibration adaptive precision electrochemical machining device and method for flexible media, specifically relating to the field of electrochemical machining. It includes an ultrasonic transducer with a spindle. A cathode tool is mounted at the other end of the spindle. The spindle drives the cathode tool to induce the desired compression deformation of the flexible media. The cathode tool is a conductive convex tool, fixedly connected to an electric lead block. The flexible media is disposed on the cathode tool, with the conductivity increasing in the compressed portion. An anode workpiece is disposed on the other side of the flexible media. This invention solves the problem of cumbersome operation in existing electrochemical machining methods, simplifies the work, and improves machining accuracy.

Description

Technical Field

[0001] This invention relates to the field of electrochemical machining, and in particular to an ultrasonic vibration adaptive precision electrochemical machining apparatus and method for flexible media. Background Technology

[0002] Statistics show that energy consumption caused by various forms of friction and wear accounts for approximately 30% to 50% of the world's total energy consumption, resulting in economic losses amounting to hundreds of billions of yuan. Because wear consumes significant amounts of energy and resources, and reduces the lifespan of machinery, in-depth research into tribology is of great importance. Early tribological theories considered surface roughness to be the primary cause of friction; however, surface friction coefficients obtained through ultra-precision machining actually increase rather than decrease. Therefore, once surface roughness reaches a certain level, further improvements in machining precision are largely ineffective.

[0003] With the development of manufacturing technology towards higher precision, higher efficiency, and higher flexibility, and the continuous improvement of the performance indicators of various friction pair components, higher requirements are being placed on friction pair surface strengthening technology. Textured metal surfaces can better meet these requirements. Textured friction pair surfaces have better lubricity and wear resistance, thus attracting widespread attention from scholars both domestically and internationally.

[0004] In previous studies of microtextured electrochemical machining, stray corrosion has significantly impacted machining accuracy. Stray corrosion typically occurs on surfaces adjacent to the machining area, which are exposed to electrolyte flow and electric fields, leading to poor dissolution and inadequate precision control. While fixed auxiliary electrodes can significantly reduce stray corrosion, they are often located at a distance from the machining area, necessitating additional process steps to eliminate stray currents, making the actual operation cumbersome. This invention effectively solves these problems, simplifying the actual machining process. Summary of the Invention

[0005] The present invention aims to provide an ultrasonic vibration adaptive precision electrolytic machining device and method for flexible media, which solves the problem of cumbersome actual operation of existing electrolytic machining methods.

[0006] To achieve the above objectives, one technical solution of the present invention is as follows: an ultrasonic vibration adaptive precision electrolytic machining device for flexible media, comprising an ultrasonic transducer, a spindle on the ultrasonic transducer, a cathode tool mounted at the other end of the spindle, the spindle driving the cathode tool to cause the flexible media to undergo the required compression deformation, the cathode tool being a conductive convex tool, a current-leading block fixedly connected to the cathode tool, a flexible medium on the cathode tool, the conductivity of the portion of the flexible medium compressed by the cathode tool increasing, and an anode workpiece on the other side of the flexible medium.

[0007] The principle and effect of the technical solution: Before the device starts working, the initial conductivity of the flexible medium is extremely low, and it can be considered approximately non-conductive. However, as the spindle drives the cathode tool to cause the flexible medium to undergo the required compression deformation, the conductivity of the flexible medium increases with the increase of pressure. Because the conductivity of the part of the flexible medium compressed by the cathode tool increases, while the conductivity of the remaining part is very low, a differential pressure is formed between the processing area and the non-processing area, achieving the processing effect of suppressing stray corrosion in the non-processing area and improving the forming accuracy of the processing area. At this time, the ultrasonic transducer transmits ultrasonic vibration to the cathode tool through the spindle, thereby removing the passivation film formed on the surface of the anode workpiece due to electrolytic machining; thus accurately replicating the cathode surface shape and achieving uniform texture processing.

[0008] Furthermore, the cathode tool is machined with circular, rectangular, or elliptical shapes.

[0009] Furthermore, the different compression depths of the flexible medium result in different voltages; the relationship between the compression amount Δh of the flexible medium and the voltage U1 it receives is: U1=λΔh, where λ is the proportionality coefficient between voltage and compression amount.

[0010] Furthermore, the differential pressure between the cathode tool and the anode workpiece is U; the voltage obtained when the flexible medium is compressed to its maximum depth is U. 1max UU 1max =U2, where U2 is the differential pressure formed between the anode workpiece surface and the cathode, and U2 is greater than the minimum breakdown voltage of the passivation film formed on the anode processing surface.

[0011] Another technical solution provided by the present invention: a processing method for a flexible medium ultrasonic vibration adaptive precision electrolytic machining device, comprising the following steps:

[0012] S1: Assemble the ultrasonic transducer with the upper end of the spindle so that the ultrasonic transducer can transmit ultrasonic vibrations to the cathode tool through the spindle, thereby removing the passivation film formed on the surface of the anode workpiece due to electrolytic machining.

[0013] S2: Assemble the cathode tool, which matches the shape of the microtexture to be processed, with the lower end of the spindle, keeping the lower end face of the cathode tool flat against the upper surface of the flexible medium, so that the processing effect of the processing area remains consistent.

[0014] S3: Place the anode workpiece in an ultrasonic cleaner and clean it three times with water, alcohol, and water respectively.

[0015] S4: Place the flexible medium on the upper surface of the anode workpiece and immerse it in a 10% sodium nitrate solution;

[0016] S5: Connect the power supply, connect the cathode tool to the negative terminal of the power supply, and connect the anode workpiece to the positive terminal of the power supply, maintaining a voltage difference U between the two.

[0017] S6: The voltage obtained when the flexible medium 5 is compressed to its maximum depth is U. 1max UU 1max =U2, where U2 is the differential pressure formed between the anode workpiece surface and the cathode, and U2 is greater than the minimum breakdown voltage of the passivation film formed on the anode processing surface;

[0018] S7: Turn on the power. Under the combined action of the electric field and the flow field, an electrochemical reaction is formed on the surface of the anode workpiece to carry out corrosion processing. When the surface of the anode workpiece meets the processing requirements, disconnect the electrolytic processing power supply, take out the anode workpiece, put it into an ultrasonic cleaner for cleaning, and complete the processing.

[0019] Compared with existing technologies, the beneficial effects of this solution are:

[0020] 1. This invention uses a flexible medium to create a differential pressure between the processed and unprocessed areas by adjusting the amount of compression. This reduces or even eliminates stray corrosion and provides excellent protection for the unprocessed areas.

[0021] 2. The flexible dielectric of this invention can be adapted to any cathode tool, thereby meeting the requirements for microtexturing of various shapes. Furthermore, the flexible dielectric can be placed between the anode and cathode, making the operation simple and convenient for actual processing. Attached Figure Description

[0022] Figure 1 This is a schematic diagram of an ultrasonic vibration adaptive precision electrolytic machining device for flexible media according to the present invention. Detailed Implementation

[0023] The present invention will be further described in detail below through specific embodiments:

[0024] The reference numerals in the accompanying drawings include: ultrasonic transducer 1, spindle 2, cathode tool 3, lead block 4, flexible dielectric 5, anode workpiece 6.

[0025] Example

[0026] like Figure 1As shown, an ultrasonic vibration adaptive precision electrolytic machining device for flexible media includes an ultrasonic transducer 1, a spindle 2 mounted on the ultrasonic transducer 1, and the ultrasonic transducer 1 bolted to the upper end of the spindle 2. Driven by a motor on the spindle 2, the ultrasonic transducer 1 can perform feed motion along the Z-axis. A cathode tool 3 is bolted to the lower end of the spindle 2. The spindle 2 drives the cathode tool 3 to induce the required compression deformation of the flexible media 5. A current-inducing block 4 is fixedly connected to the side wall of the cathode tool 3, facilitating power connection. The bottom of the cathode tool 3 contacts the flexible media 5. The cathode tool 3 is a conductive convex tool; its bottom can be either convex or non-convex, and can be machined into various shapes such as circular, rectangular, and elliptical. The flexible media 5 has extremely low conductivity in its initial uncompressed state, almost acting as an insulator. However, the conductivity of the flexible media 5 increases with increasing pressure. Therefore, the conductivity of the portion of the flexible medium 5 compressed by the cathode tool 3 increases, while the conductivity of the remaining portion is very small, thus creating a differential pressure between the processed and unprocessed areas. This achieves the processing effect of suppressing stray corrosion in the unprocessed area and improving the forming accuracy of the processed area. The bottom of the flexible medium 5 contacts the anode workpiece 6, which is immersed in the electrolyte during operation. In this embodiment, the ultrasonic transducer 1 transmits ultrasonic vibrations to the cathode tool 3 through the spindle 2, thereby removing the passivation film formed on the surface of the anode workpiece 6 due to electrolytic processing; thus accurately replicating the cathode surface shape and achieving uniform texture processing.

[0027] During use, the ultrasonic transducer 1 drives the spindle 2 to perform axial high-frequency vibration, periodically compressing the flexible medium 5; and removes the passivation film formed on the anode workpiece 6 by electrolytic machining through ultrasonic vibration. In this embodiment, cathode tools 3 with through holes of different shapes can be assembled. The different compression depths of the flexible medium 5 result in different voltages. The relationship between the compression amount Δh of the flexible medium 5 and its voltage U1 can be approximated as U1 = λΔh, where λ is the proportionality coefficient between voltage and compression amount. The flexible medium 5, by applying different pressures, creates a certain voltage difference between the machined and unmachined surfaces of the anode workpiece 6. The differential pressure between the cathode tool 3 and the anode workpiece 6 is U; the voltage obtained when the flexible medium 5 is compressed to its maximum depth is U0. 1max UU 1max =U2, where U2 is the differential pressure formed between the surface of the anode workpiece 6 and the cathode, and U2 is greater than the minimum breakdown voltage of the passivation film formed on the anode processing surface.

[0028] The processing method in this embodiment is as follows:

[0029] S1: Assemble the ultrasonic transducer 1 with the upper end of the spindle 2 so that the ultrasonic transducer 1 can transmit ultrasonic vibrations to the cathode tool 3 through the spindle 2, thereby removing the passivation film formed on the surface of the anode workpiece 6 due to electrolytic machining.

[0030] S2: Assemble the cathode tool 3, which is consistent with the shape of the microtexture to be processed, with the lower end of the spindle 2, keeping the lower end face of the cathode tool 3 flat against the upper surface of the flexible medium 5, so that the processing effect of the processing area is consistent.

[0031] S3: Place the anode workpiece 6 into an ultrasonic cleaner and clean it three times with water, alcohol, and water respectively.

[0032] S4: Place the flexible medium 5 on the upper surface of the anode workpiece 6 and immerse it in a 10% sodium nitrate solution.

[0033] S5: Connect the power supply. Connect the cathode tool 3 to the negative terminal of the power supply and the anode workpiece 6 to the positive terminal of the power supply, maintaining a voltage difference U between them.

[0034] S6: The voltage obtained when the flexible medium 5 is compressed to its maximum depth is U. 1max UU 1max =U2, where U2 is the differential pressure formed between the surface of the anode workpiece 6 and the cathode, and U2 is greater than the minimum breakdown voltage of the passivation film formed on the anode processing surface.

[0035] S7: Turn on the power. Under the combined action of the electric field and the flow field, an electrochemical reaction is formed on the surface of the anode workpiece 6 to carry out corrosion processing. When the surface of the anode workpiece 6 meets the processing requirements, disconnect the electrolytic processing power supply, take out the anode workpiece 6, put it into an ultrasonic cleaner for cleaning, and complete the processing.

[0036] The above are merely embodiments of the present invention, and common knowledge such as specific structures and / or characteristics in the solutions are not described in detail here. It should be noted that those skilled in the art can make various modifications and improvements without departing from the structure of the present invention, and these should also be considered within the scope of protection of the present invention. These modifications and improvements will not affect the effectiveness of the implementation of the present invention or the practicality of the patent. The scope of protection claimed in this application should be determined by the content of its claims, and the specific embodiments described in the specification can be used to interpret the content of the claims.

Claims

1. An ultrasonic vibration adaptive precision electrolytic machining device for flexible media, characterized in that: Includes an ultrasonic transducer (1), on which a main shaft (2) is provided, and a cathode tool (3) is mounted at the other end of the main shaft (2). The main shaft (2) drives the cathode tool (3) to cause the flexible medium (5) to undergo the required compression deformation. The cathode tool (3) is a conductive convex tool. The cathode tool (3) is fixedly connected to an electric lead block (4). The cathode tool (3) is provided with a flexible medium (5). The conductivity of the part of the flexible medium (5) compressed by the cathode tool (3) increases. An anode workpiece (6) is provided on the other side of the flexible medium (5). The different compression depths of the flexible medium (5) result in different voltages; the compression amount of the flexible medium (5) Rather than the voltage The relationship between them is: , This is the ratio of voltage to compression. The differential pressure between the cathode tool (3) and the anode workpiece (6) is U; the voltage obtained when the flexible medium (5) is compressed to its maximum depth is ; , The differential pressure formed between the surface of the anode workpiece (6) and the cathode, and It is greater than the minimum breakdown voltage of the passivation film formed on the anodic surface.

2. The ultrasonic vibration adaptive precision electrolytic machining device for flexible media according to claim 1, characterized in that: The cathode tool (3) is machined with circular, rectangular and elliptical shapes.

3. A processing method for an ultrasonic vibration adaptive precision electrolytic machining apparatus for flexible media according to claim 1: characterized in that: Includes the following steps: S1: Assemble the ultrasonic transducer (1) with the upper end of the spindle (2) so that the ultrasonic transducer (1) can transmit ultrasonic vibrations through the spindle (2) to the cathode tool (3), thereby removing the passivation film formed on the surface of the anode workpiece (6) due to electrolytic processing. S2: Assemble the cathode tool (3) that matches the microtexture shape to be processed with the lower end of the spindle (2), keeping the lower end face of the cathode tool (3) flat against the upper surface of the flexible medium (5), so that the processing effect of the processing area remains consistent. S3: Place the anode workpiece (6) into an ultrasonic cleaner and clean it three times. The cleaning solutions are water, alcohol and water, respectively. S4: Place the flexible medium (5) on the upper surface of the anode workpiece (6) and immerse it in a 10% sodium nitrate solution; S5: Connect the power supply, connect the cathode tool (3) to the negative terminal of the power supply, and connect the anode workpiece (6) to the positive terminal of the power supply, maintaining a voltage difference U between the two; S6: The voltage obtained when the flexible medium (5) is compressed to its maximum depth is ; , The differential pressure formed between the surface of the anode workpiece (6) and the cathode, and It is greater than the minimum breakdown voltage of the passivation film formed on the anodic surface; S7: Connect the power supply. Under the combined action of the electric field and the flow field, an electrochemical reaction is formed on the surface of the anode workpiece (6) to carry out corrosion processing. When the surface of the anode workpiece (6) meets the processing requirements, disconnect the electrolytic processing power supply, take out the anode workpiece (6), put it into an ultrasonic cleaner for cleaning, and complete the processing.

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