Electrochemical grinding assisted machining device and method based on light-controlled composite material
By using an electrochemical grinding-assisted processing device based on photo-controlled composite materials, the processing gap is controlled by the expansion or contraction of the deformed matrix under laser irradiation. This solves the problems of electrolyte loss and grinding failure, and enables efficient and high-quality electrochemical processing of materials such as titanium alloys.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Patents(China)
- Current Assignee / Owner
- JIANGSU UNIV
- Filing Date
- 2024-03-28
- Publication Date
- 2026-07-14
AI Technical Summary
In electrochemical machining, rapid electrolyte loss and excessive machining gaps can lead to grinding failure, affecting the efficient and high-quality machining of difficult-to-machine materials such as titanium alloys.
An electrochemical grinding-assisted processing device using photo-controlled composite materials, by coating a deformable matrix around a tube electrode, uses laser irradiation to control the expansion and contraction of the deformable matrix under different radio frequencies, thereby real-time regulating the processing gap and product discharge, ensuring that the electrolyte participates in the reaction and effectively discharges the processing products.
It improves the efficiency and stability of electrochemical grinding, prevents electrolyte loss and impurity retention, and enhances processing quality and efficiency.
Smart Images
Figure CN118023641B_ABST
Abstract
Description
Technical Field
[0001] This invention belongs to the field of special processing technology, and in particular relates to an electrochemical grinding auxiliary processing device and method based on photosensitive composite materials. Background Technology
[0002] With the development of the aerospace industry, titanium alloys, which are resistant to high temperatures, corrosion, and have high specific strength, are increasingly being used for parts in aerospace engineering. These titanium alloy parts are large in size and complex in shape, and usually need to be machined from a single blank. Using traditional machining methods can easily lead to problems such as severe tool wear and long machining cycles.
[0003] Because electrochemical machining (ECM) is not limited by the toughness and hardness of the workpiece material, and because there is no tool electrode wear, it offers high machining efficiency. Some researchers have proposed using ECM to achieve efficient and high-quality machining of titanium alloy parts. In deep machining, due to the difficulty of external electrolyte supply, some researchers have proposed an internal spray ECM method. In this method, the electrolyte is sprayed from a hollow tube electrode onto the anode workpiece surface for electrochemical machining. This internal spray method ensures a sufficient supply of electrolyte in the machining area during deep machining, improving the stability and single-pass machining depth. However, a dense oxide layer continuously forms on the workpiece surface during machining, affecting the efficiency of the electrochemical reaction. Furthermore, some insoluble substances in the workpiece material can also cause machining problems. To address this issue, electrochemical grinding has emerged. This method can significantly improve the stability of efficient electrochemical machining processes. However, in actual processing, due to the principles of fluid mechanics and the influence of gravity, it is difficult to ensure the uniformity and stability of the processing gap throughout the entire electrochemical machining area. This can easily lead to a large amount of electrolyte loss from the processing gap, making it impossible to stably control the electrolyte level in the machining area. Spark discharge will occur in some areas with insufficient electrolyte, which can severely damage the tool electrode and workpiece surface. Furthermore, an excessively large processing gap will cause the grinding action of the abrasive grains on the tool electrode surface to fail.
[0004] Solving the problems of rapid electrolyte loss from the machining gap and grinding failure when the machining gap is too large during electrochemical machining is the key to achieving efficient and high-quality electrochemical grinding of difficult-to-machine materials such as titanium alloys. Summary of the Invention
[0005] The purpose of this invention is to provide an electrochemical grinding auxiliary processing device and method based on photo-controlled composite materials to solve the above-mentioned problems. By controlling laser irradiation to change the external shape of the electrochemical processing tool in real time, the external shape of the electrochemical processing tool can be changed in real time, thereby realizing real-time control of the electrochemical processing state and improving processing quality and efficiency.
[0006] To achieve the above objectives, the present invention provides the following solution: an electrochemical grinding auxiliary processing device based on photosensitive composite materials, comprising a tube electrode and an anode workpiece, wherein when the anode workpiece is electrochemically ground by the tube electrode, a processing gap is formed between the tube electrode and the anode workpiece, characterized in that it further comprises:
[0007] Deformation substrate, used to coat the outside of the tube electrode;
[0008] The deformable substrate is configured to expand under a first radio frequency irradiation. When the deformable substrate expands, it can fill the processing gap formed between the tube electrode and the anode workpiece. Under a second radio frequency irradiation, it contracts. When the deformable substrate contracts, a new processing gap is generated between the tube electrode and the anode workpiece to discharge the processing products generated during processing.
[0009] A light source for illuminating the deformed substrate and capable of switching between a first radio frequency or a second radio frequency;
[0010] The control mechanism includes a first operating mode and a second operating mode. In the first operating mode, the control mechanism controls the light source to emit rays at a first radio frequency. In the second operating mode, the control mechanism controls the light source to emit rays at a second radio frequency.
[0011] Preferably, the deformable matrix has a multi-layer structure, and the outermost layer of the deformable matrix has the highest coefficient of thermal expansion.
[0012] Preferably, the coefficient of thermal expansion of the deformable matrix gradually increases outward from the axis of the tube electrode.
[0013] Preferred options also include:
[0014] A plurality of grinding particles are provided, which are arranged circumferentially at equal intervals on the outer wall surface of the deformable substrate and fixed to the deformable substrate. The grinding particles are configured to slide in contact with the anode workpiece when the deformable substrate expands.
[0015] Preferably, the portion of the outer wall of the deformable substrate located at the bottom of the tube electrode is covered with an insulating layer.
[0016] Preferably, the tube electrode has a cavity inside, and the side wall of the cavity has a plurality of jet holes that penetrate the deformable substrate. The jet holes are configured such that when the tube electrode rotates at high speed, the electrolyte flows through the plurality of jet holes in the direction from the cavity to the anode workpiece.
[0017] Preferred options also include:
[0018] An electrolyte circulation mechanism is configured to be connected to the tube electrode for introducing electrolyte into the containment cavity.
[0019] A method for electrochemical grinding-assisted machining based on photo-controlled composite materials is also provided. Based on the aforementioned electrochemical grinding-assisted machining device based on photo-controlled composite materials, the method further includes the following steps:
[0020] Connect the tube electrode to the positive terminal of the power supply and the anode workpiece to the negative terminal of the power supply.
[0021] The tube electrode is rotated at high speed and ground in contact with the anode workpiece.
[0022] During the grinding process, the deformed substrate is irradiated by a light source, and selective switching is performed between the first radio frequency and the second radio frequency.
[0023] By monitoring the degree of grinding of the anode workpiece, the tube electrode stops rotating when the grinding of the anode workpiece is completed.
[0024] Preferably, when the deformed substrate is irradiated by a light source, the light source is adjusted by a control mechanism to periodically switch between the first radio frequency and the second radio frequency.
[0025] Preferably, when the tube electrode rotates at high speed and contacts the anode workpiece, electrolyte is introduced into the tube electrode through an electrolyte circulation mechanism until the grinding is completed.
[0026] Compared with the prior art, the present invention has the following advantages and technical effects:
[0027] This invention utilizes a deformable matrix coating the outer layer of the tube electrode. The deformable matrix's structural characteristics—expansion and contraction under different radio frequency laser irradiation—allow it to fill the machining gap between the tube electrode and the anode workpiece during expansion. This prevents the electrolyte from rapidly flowing out of the gap during grinding due to excessive clearance, effectively enhancing the electrolyte's participation in the electrochemical reaction and improving the electrochemical grinding effect. Simultaneously, the expanded deformable matrix ensures effective contact between the tube electrode and the anode workpiece, preventing grinding failure caused by an excessively large machining gap. Ultimately, this invention improves… The electrochemical machining process offers advantages in efficiency and stability. Furthermore, because the deformed substrate undergoes structural shrinkage under the influence of laser radio frequency, a new machining gap is created between the deformed substrate covering the tube electrode and the anode workpiece during this shrinkage. This gap allows for the removal of machining products generated during grinding. Since this machining gap is controlled by adjusting the switching of the light source between the first and second radio frequencies via a control mechanism, the removal of machining products is controlled. This effectively prevents the retention of electrolyte containing impurities and grinding impurities in the machining area, reducing their adverse effects on subsequent electrochemical reactions and further improving machining quality. Attached Figure Description
[0028] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the embodiments will be briefly described below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.
[0029] Figure 1 This is a schematic diagram of the deformable substrate and the tube electrode.
[0030] Figure 2 This diagram shows the positional relationship between the deformed matrix and the outermost deformed matrix.
[0031] Figure 3 This is a schematic diagram of the structure of the deformed matrix under expansion state;
[0032] Figure 4 This is a schematic diagram of the structure of the deformed matrix under contraction conditions.
[0033] Figure 5 This is a comparison diagram of the grinding effects of a traditional grinding device and the grinding effect of this patent.
[0034] Figure 6 This diagram shows the connection relationship between the electrolyte circulation mechanism and the tube electrode.
[0035] The components include: 1. Anode workpiece; 2. Insulation layer; 3. Deformation matrix; 4. Outermost deformation matrix; 5. Grinding particles; 6. Light source; 7. Servo motor; 8. Motion control card; 9. Rotary joint; 10. Data acquisition card; 11. Power supply; 12. Computer; 13. Pressure gauge; 14. Filter; 15. Valve; 16. Pump; 17. Clear liquid tank; 18. Turbid liquid tank. Detailed Implementation
[0036] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.
[0037] To make the above-mentioned objects, features and advantages of the present invention more apparent and understandable, the present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments.
[0038] Example: Refer to Figures 1-6 An electrochemical grinding auxiliary processing device based on photosensitive composite materials includes a tube electrode and an anode workpiece 1. When electrochemical grinding is performed on the anode workpiece 1 through the tube electrode, a processing gap is formed between the tube electrode and the anode workpiece 1. The device is characterized by further comprising:
[0039] Deformation substrate 3 is used to coat the outside of the tube electrode;
[0040] The deformable substrate 3 is configured to expand under the first radio frequency irradiation. When the deformable substrate 3 expands, it can fill the processing gap formed between the tube electrode and the anode workpiece 1. And it will shrink under the second radio frequency irradiation. When the deformable substrate 3 shrinks, a new processing gap can be generated between the tube electrode and the anode workpiece 1 to discharge the processing products generated during processing.
[0041] Light source 6 is used to irradiate the deformed substrate 3 and can switch between a first radio frequency or a second radio frequency;
[0042] The control mechanism includes a first working mode and a second working mode. In the first working mode, the control mechanism controls the light source 6 to emit rays at a first radio frequency. In the second working mode, the control mechanism controls the light source 6 to emit rays at a second radio frequency.
[0043] This invention utilizes the structural characteristics of the deformable substrate 3, which expands or contracts under different radio frequency laser irradiations, to fill the processing gap between the tube electrode and the anode workpiece 1 when the deformable substrate 3 expands. This prevents the electrolyte from flowing out rapidly during grinding due to an excessively large gap, effectively improving the electrolyte's participation in the electrochemical reaction and enhancing the electrochemical grinding effect. Simultaneously, the expanded deformable substrate 3 effectively ensures the contact between the tube electrode and the anode workpiece 1, preventing the grinding action from failing due to an excessively large processing gap. Ultimately, this improves the efficiency and stability of electrochemical processing.
[0044] Furthermore, since the deformable substrate 3 can also shrink under the condition of radio frequency change, a new processing gap is generated between the deformable substrate 3 covering the tube electrode and the anode workpiece 1 when the deformable substrate 3 shrinks. This gap is used to discharge the processing products generated during the grinding process. Since the processing gap is controlled by the control mechanism by adjusting the light source 6 and switching between the first radio frequency and the second radio frequency, the discharge of processing products is controlled. This effectively prevents the electrolyte containing impurities and the impurities ground off from the grinding process from remaining in the processing area, reducing their adverse effects on the subsequent electrochemical reaction and further improving the processing quality.
[0045] This technical solution also provides a light source 6, which is used to apply adjustable laser radio frequency to the deformable substrate 3 covered by the tube electrode, thereby realizing the state of the light source 6 switching between the first radio frequency and the second radio frequency through the control mechanism, irradiating the surface of the deformable substrate 3, causing the deformable substrate 3 to generate corresponding structural deformation, and improving the quality and efficiency of electrochemical grinding by controlling the expansion or contraction of the deformable substrate 3.
[0046] Understandably, in this technical solution, the light source 6 preferably adopts, but is not limited to, a laser emitter with adjustable laser emission frequency, or a laser irradiator electrically connected to a frequency modulation controller. The computer 12 communicates with the light source 6 to achieve control of the laser radio frequency. The principle of laser frequency modulation via the computer 12 is existing technology and will not be described in detail.
[0047] Furthermore, the control mechanism in this technical solution includes a computer 12 and a power supply 11. The computer 12 is connected to a motion control card 8 and a data acquisition card 10, respectively, for monitoring the grinding process. A conventional servo motor 7 is used to drive the tube electrode to rotate and grind the anode workpiece 1. After the grinding process is completed, the servo motor 7 is controlled to stop through the PLC control terminal. The control of the start and stop of the servo motor 7 during the tube electrode grinding process is existing technology and will not be described in detail.
[0048] In this technical solution, a photosensitive elastic metal-based composite layer structure is used to prepare the deformable substrate 3, such as beryllium copper alloy. By utilizing its high coefficient of thermal expansion and good electrical conductivity and heat resistance, the deformable substrate 3 can be controlled to expand or contract by adjusting the laser radio frequency targeting the deformable substrate 3, thus ensuring the effect of changing the external shape of the electrochemical grinding auxiliary processing device.
[0049] Furthermore, the deformable matrix 3 has a multi-layer structure, and the outermost layer of the deformable matrix 3 has the highest coefficient of thermal expansion.
[0050] In this technical solution, the deformable substrate 3 adopts a multi-layer structure, and the outermost deformable substrate 4 in the multi-layer deformable substrate 3 has the highest coefficient of thermal expansion. Under the action of laser irradiation, due to the difference in the coefficients of thermal expansion between the inner and outer layers, it is effectively ensured that the outermost layer of the deformable substrate 3 can expand in the direction from the axis of the tube electrode outward, thereby filling the processing gap.
[0051] Furthermore, the coefficient of thermal expansion of the deformed substrate 3 gradually increases outward along the axis of the tube electrode.
[0052] In summary, when the deformable substrate 3 has at least three layers, by gradually increasing the coefficient of thermal expansion of the deformable substrate 3 outward along the axis of the tube electrode, the outermost deformable substrate 4 can have the highest coefficient of thermal expansion. This also ensures that the deformable substrate 3 maintains structural stability during deformation, avoiding excessive deviation in the coefficient of thermal expansion between adjacent deformable substrates 3, which would reduce the effectiveness of deformation control and affect the quality of subsequent electrochemical grinding.
[0053] Furthermore, it also includes:
[0054] A plurality of grinding particles 5 are provided, and the plurality of grinding particles 5 are arranged at equal intervals in the circumferential direction on the outer wall surface of the deformable substrate 3 and fixed to the deformable substrate 3. The grinding particles 5 are configured to slide in contact with the anode workpiece 1 when the deformable substrate 3 expands.
[0055] By providing several grooves on the outer wall of the deformable substrate 3, the grinding particles 5 are preferably, but not limited to, diamond abrasive grains. By embedding the diamond abrasive grains one by one into the grooves, the grinding particles 5 are fixed to the deformable substrate 3 and move relative to the surface of the anode workpiece 1 when the deformable substrate 3 expands or contracts. When the deformable substrate 3 expands, several grinding particles 5 slide in contact with the surface of the anode workpiece 1, thereby improving grinding efficiency, facilitating the finishing of the processed surface, and ensuring grinding quality.
[0056] Furthermore, the portion of the outer wall surface of the deformable substrate 3 located at the bottom of the tube electrode is covered with an insulating layer 2.
[0057] By covering the portion of the outer wall surface of the deformable substrate 3 located at the bottom of the tube electrode with an insulating layer 2, and when the deformable substrate 3 has a multi-layer structure, the bottom of several layers of the deformable substrate 3 are covered with an insulating layer 2. Not only is the insulating layer 2 at the bottom almost unaffected by the heat of the tube electrode when the laser irradiates the deformable substrate 3, but the arrangement of the insulating layer 2 can also prevent the bottom end of the tube electrode from forming a wire circuit with the surface of the anode workpiece 1. As a result, stray corrosion is significantly reduced during the grinding process, and the processing quality is further improved.
[0058] Furthermore, the tube electrode has a defined cavity inside, and the side wall of the cavity is provided with several jet holes that penetrate the deformable substrate 3. The jet holes are configured such that when the tube electrode rotates at high speed, the electrolyte flows through the several jet holes in the direction from the cavity to the anode workpiece 1.
[0059] Reference Figures 3-5 The high-speed rotation of the tube electrode grinds the surface of the anode workpiece 1. The centrifugal force generated during the rotation can guide the electrolyte in the tube electrode through the jet hole and spray it directly onto the surface of the anode workpiece 1, thereby enhancing the uniformity of electrochemical machining on the surface of the anode workpiece 1. At the same time, it provides the flow power of the electrolyte. Under the premise that the expansion or contraction of the deformable substrate 3 can be controlled, the expansion fills the machining gap and reduces electrolyte overflow, while the contraction generates new machining gaps. The electrolyte with flow power can quickly discharge the machining products generated by electrochemical machining, effectively improving the machining efficiency.
[0060] Furthermore, it also includes an electrolyte circulation mechanism, configured to be connected to the tube electrode for introducing electrolyte into the containment cavity.
[0061] Reference Figure 6 In this technical solution, the electrolyte circulation mechanism uses a rotary joint 9, a pump 16, and a valve 15 to connect one end of the tube electrode to the clear liquid tank 17. A pressure gauge 13 is installed at the connection end between the clear liquid tank 17 and the rotary joint 9 to circulate electrolyte to the tube electrode during grinding and ensure safety. The processing waste liquid discharged during grinding is collected by a collection tank. One side of the collection tank is connected to a turbid liquid tank 18. A filter 14 is installed between the turbid liquid tank 18 and the clear liquid tank 17 to filter the electrolyte and realize the recycling of the electrolyte.
[0062] A method for electrochemical grinding-assisted machining based on photo-controlled composite materials is also provided. Based on the aforementioned electrochemical grinding-assisted machining device based on photo-controlled composite materials, the method further includes the following steps:
[0063] Connect the tube electrode to the positive terminal of power supply 11, and connect the anode workpiece 1 to the negative terminal of power supply 11.
[0064] The tube electrode is rotated at high speed and ground in contact with the anode workpiece 1;
[0065] During the grinding process, the deformed substrate 3 is irradiated by the light source 6, and selective switching is performed between the first radio frequency and the second radio frequency.
[0066] By monitoring the degree of grinding of the anode workpiece 1, the tube electrode stops rotating when the grinding of the anode workpiece 1 is completed.
[0067] Furthermore, when the deformed substrate 3 is irradiated by the light source 6, the light source 6 is adjusted by the control mechanism to periodically switch between the first radio frequency and the second radio frequency.
[0068] The control mechanism controls the radio frequency irradiated by the light source 6 to change periodically between the first radio frequency and the second radio frequency, thereby achieving periodic deformation of the deformable substrate 3. This allows the processing products during the grinding process to be discharged in a wave-like manner, which enhances the removal effect, especially for products that are difficult to remove from the surface of the anode workpiece 1 and the deformable substrate 3.
[0069] Furthermore, when the tube electrode rotates at high speed and contacts the anode workpiece 1, electrolyte is introduced into the tube electrode through the electrolyte circulation mechanism until the grinding is completed.
[0070] In the description of this invention, it should be understood that the terms "longitudinal", "lateral", "up", "down", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing this invention, and are not intended to 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 of this invention.
[0071] The embodiments described above are merely preferred embodiments of the present invention and are not intended to limit the scope of the present invention. Various modifications and improvements made by those skilled in the art to the technical solutions of the present invention without departing from the spirit of the present invention should fall within the protection scope defined by the claims of the present invention.
Claims
1. An electrochemical grinding auxiliary processing device based on photosensitive composite material, comprising a tube electrode and an anode workpiece (1), wherein when the anode workpiece (1) is electrochemically ground by the tube electrode, a processing gap is formed between the tube electrode and the anode workpiece (1), characterized in that, Also includes: Deformation substrate (3) is used to coat the outside of the tube electrode; The deformable substrate (3) is configured to expand under the first radio frequency irradiation. When the deformable substrate (3) expands, it can fill the processing gap formed between the tube electrode and the anode workpiece (1). Under the second radio frequency irradiation, it shrinks. When the deformable substrate (3) shrinks, a new processing gap can be generated between the tube electrode and the anode workpiece (1) to discharge the processed product. A light source (6) is used to irradiate the deformed substrate and can be switched between a first radio frequency or a second radio frequency; The control mechanism includes a first working mode and a second working mode. In the first working mode, the control mechanism controls the light source (6) to emit rays at a first radio frequency. In the second working mode, the control mechanism controls the light source (6) to emit rays at a second radio frequency.
2. The electrochemical grinding-assisted machining device based on photo-controlled composite materials according to claim 1, characterized in that: The deformable matrix (3) has a multi-layer structure, and the outermost layer of the deformable matrix (3) has the highest coefficient of thermal expansion.
3. The electrochemical grinding-assisted machining device based on photo-controlled composite materials according to claim 1, characterized in that: The coefficient of thermal expansion of the deformable substrate (3) gradually increases outward along the axis of the tube electrode.
4. The electrochemical grinding-assisted machining device based on photo-controlled composite materials according to claim 1, characterized in that, Also includes: A plurality of grinding particles (5) are provided, and the plurality of grinding particles (5) are arranged circumferentially at equal intervals on the outer wall surface of the deformable substrate (3) and fixed to the deformable substrate (3). The grinding particles (5) are configured to slide in contact with the anode workpiece (1) when the deformable substrate (3) expands.
5. The electrochemical grinding-assisted machining device based on photo-controlled composite materials according to claim 1, characterized in that: The outer wall of the deformable substrate (3) located at the bottom of the tube electrode is covered with an insulating layer (2).
6. The electrochemical grinding-assisted machining device based on photo-controlled composite materials according to claim 1, characterized in that: The tube electrode has a cavity inside, and the side wall of the cavity is provided with a plurality of jet holes that penetrate the deformable substrate (3). The jet holes are configured such that when the tube electrode rotates at high speed, the electrolyte flows through the plurality of jet holes in the direction from the cavity to the anode workpiece (1).
7. The electrochemical grinding-assisted machining device based on photo-controlled composite materials according to claim 6, characterized in that, Also includes: An electrolyte circulation mechanism is configured to be connected to the tube electrode for introducing electrolyte into the containment cavity.
8. An electrochemical grinding-assisted machining method based on photosensitive composite materials, using the electrochemical grinding-assisted machining apparatus based on photosensitive composite materials as described in any one of claims 1-7, characterized in that, It also includes the following steps: Connect the tube electrode to the positive terminal of the power supply, and connect the anode workpiece (1) to the negative terminal of the power supply; The tube electrode is rotated at high speed and ground in contact with the anode workpiece (1); During the grinding process, the deformed substrate (3) is irradiated by a light source (6), and selective switching is performed between the first radio frequency and the second radio frequency. By monitoring the degree of grinding of the anode workpiece (1), the tube electrode stops rotating when the grinding of the anode workpiece (1) is completed.
9. The electrochemical grinding-assisted machining method based on photosensitive composite materials according to claim 8, characterized in that: When the deformed substrate (3) is irradiated by the light source (6), the light source (6) is adjusted by the control mechanism to make the first radio frequency and the second radio frequency switch periodically.
10. The electrochemical grinding-assisted machining method based on photosensitive composite materials according to claim 8, characterized in that: When the tube electrode rotates at high speed and contacts the anode workpiece (1), electrolyte is introduced into the tube electrode through the electrolyte circulation mechanism until the grinding is completed.