Electrochemical gradient thickening-ultrasonic shearing composite rheological manufacturing method and device

Abstract

The invention relates to an electrochemical gradient thickening-ultrasonic shearing composite rheology manufacturing method, which comprises the following steps: dissolving the anode surface of a workpiece and forming a passive film by utilizing an electrochemical interface reaction, inducing nano abrasive particles in a suspension to generate an aggregation effect by thermosensitive particles, and shearing and removing a material by utilizing a flexible ultrasonic fluid grinding tool. The invention further provides an electrochemical gradient thickening-ultrasonic shearing composite rheology manufacturing device. The electrochemical gradient thickening-ultrasonic shearing composite rheology manufacturing device comprises an ultrasonic auxiliary device, a power supply auxiliary device, an electrochemical gradient thickening polishing solution circulation auxiliary device, a temperature control device and a polishing device. According to the method, the polishing efficiency can be greatly improved, and the near-atomic-scale polishing precision of atoms can be achieved.

Description

Technical Field

[0001] The present invention belongs to the field of ultra-precision manufacturing, and particularly relates to an electrochemical gradient thickening-ultrasonic shearing composite rheological manufacturing method and device. Background Art

[0002] Internal flow channel components made of titanium alloy are widely used in many fields such as aerospace, medical, automotive, and chemical industries. For example, in the cooling systems of automobiles and rockets, it is used for conformal cooling channels and heat exchangers, and fluid power components such as fuel nozzles in aero-engines, which ensure stable combustion and improve combustion efficiency. In addition, in the field of biochemistry, it is also used as a carrier for physical and chemical micro-reactions, such as micro-channel reactors. In the aerospace and military fields, due to the good biocompatibility, oxidation resistance, and corrosion resistance of titanium alloy, it is used as a tissue engineering scaffold material. With the wide application of the internal flow channel structure of titanium alloy, various flow channel components with different structures have emerged, which can support multiple functions and meet the usage requirements of different devices. Therefore, effective finishing processing of it is an important means to improve product quality. For complex metal additive components, the fine processing of their internal surfaces has become a major challenge in current industrial applications and is also one of the main obstacles restricting the wide application of metal additive manufacturing technology. Due to the higher requirements for the internal structure and appearance accuracy of aerospace products, advanced processes need to be adopted for internal surface precision machining to improve product quality. In the aerospace field, products with functional channels can be used to transfer mass or energy, and have high requirements for the forming quality of the internal surface. However, the post-processing operations involve complex working conditions, many limiting conditions, a harsh internal working environment, and difficult processing, so the finishing processing of the internal flow channels becomes difficult. In the industrial community, the current mainstream technical means include mechanical polishing techniques (such as abrasive flow machining technology), chemical polishing, and electrochemical polishing. These methods can basically meet the requirements when dealing with simple channels, but still have obvious deficiencies in dealing with complex channels, blind holes, thin walls, variable cross-sections, and complex curved surfaces.

[0003] Electrochemical polishing technology is a surface treatment method that dissolves the anode of a metal workpiece in a specific electrochemical polishing solution environment to reduce its surface roughness, enhance the brightness, and impart metallic luster. As a means of metal surface treatment, electrochemical polishing has the following advantages: 1) It can effectively reduce the surface roughness, thus achieving excellent surface polishing effects; 2) The polishing efficiency is very high and has no direct relationship with the mechanical properties (such as hardness, toughness, strength, etc.) of the material to be treated; 3) Compared with mechanical polishing equipment, the equipment required for polishing formed parts is simpler and more economical. During the polishing process, the workpiece does not come into contact with the tool (cathode), and no cutting force, heat, burrs, or tool marks and tool wear will be generated.

[0004] The ultrasonic vibration assisted abrasive flow polishing technology (UVAFP) combines ultrasonic vibration and abrasive flow polishing methods, representing a comprehensive polishing technology. When using this process to polish metal parts, tool-free grinding can be achieved, and at the same time, the surface integrity after polishing can be improved. This technology is particularly suitable for treating the surfaces of hard and brittle materials that are difficult to polish and surfaces with complex shapes, broadening the application range of the abrasive flow polishing technology, thereby improving the polishing efficiency and the quality of the workpiece surface. The UVAFP technology can be divided into two categories according to different working principles of ultrasonic vibration: one is the polishing of parts mainly based on ultrasonic energy, and the other is the polishing of parts using the combined action mechanism of ultrasonic waves and abrasive flow. Among them, the latter mainly includes pulsed ultrasonic polishing and non-contact ultrasonic polishing. Compared with traditional polishing technologies, by adding ultrasonic treatment ability to the relative kinetic energy of abrasive grains, not only can the polishing efficiency be significantly improved, but also the polishing effect will be significantly improved.

[0005] The Chinese invention patent (CN118596004A) has been published, which is an air flow and vibration assisted electrochemical-shear rheology composite polishing device, including a workbench, a gantry and a polishing component; the workbench and the gantry form a machine frame; the polishing component is arranged on the machine frame and includes a workpiece clamping and driving component and a polishing tank; each of the two side arms of the gantry is provided with a slide rail, and the two slide rails are respectively slidably matched with the two ends of the slide table; a vibration device is arranged on the workbench; a group of nozzles is arranged on the polishing tank; an anode wire is arranged on the workpiece clamping and driving component, and a cathode wire is arranged on the polishing tank. The air flow and vibration assisted electrochemical-shear rheology composite polishing device of the present invention has a specific structure. When polishing the titanium alloy integral blisk, it can effectively prevent the problem of blockage at the blade root, enabling the titanium alloy integral blisk to be polished efficiently and evenly. Correspondingly, the present invention also provides an air flow and vibration assisted electrochemical-shear rheology composite polishing method. However, this patent cannot polish complex microchannels and metal pipes with complex shapes, and there is room for further improvement in terms of expanding the variety of parts and performance.

[0006] The Chinese invention patent (CN118345497A) has been published. It is an electrochemical polishing device, including a longitudinal torsion peristaltic mechanism and a multi-axis mechanism. The multi-axis mechanism is connected to the longitudinal torsion peristaltic mechanism to realize the relative movement between the workpiece to be polished and the electrolyte. An electrolytic cell is installed below the longitudinal torsion peristaltic mechanism. The electrolytic cell is used to hold an electrolyte composed of a pre-prepared electrolyte solution and porous microspheres that have adsorbed the electrolyte solution in advance, so that the electrolyte is stratified in the electrolytic cell. The electrolytic cell is connected to the negative pole of the power supply, and the workpiece to be polished is connected to the positive pole of the power supply. The workpiece to be polished is immersed in the upper-layer electrolyte, and a certain voltage is applied between the positive and negative poles. A heating device is installed in the electrolytic cell, and the temperature of the electrolyte is controlled at a preset temperature through a temperature control system. A porous sphere particle circulation device is also installed in the electrolytic cell to transport the porous microspheres at the bottom of the electrolytic cell to the upper part of the electrolytic cell. This device can achieve global synchronous conformal polishing of workpieces with complex shapes, improving the polishing quality and efficiency. However, this patent does not involve the ultrasonic shear polishing mechanism, and there is still room for improvement in the high-efficiency grinding and polishing of workpieces.

[0007] The Chinese invention patent (CN114985855A) has been published. It is an electrochemical-assisted mechanical polishing processing device. It includes a grinding block, a polishing vibration tank, a vibrator, a spring and a base to jointly form a mechanical processing component; a pulse power supply, a support plate, a partition plate, a cathode tube material, etc. to form an electrochemical processing component; a support shaft, a first pulley, a second pulley, a transmission belt and a driving motor to form a rotation driving component; a circulating pump, a valve, a filter, a circulating pipeline, a nozzle and a spray pipe to form a polishing liquid circulation component. In this invention, the assistance of electrochemistry expands the processing range of mechanical processing, and various metal materials with high hardness and high strength can be processed. The rolling grinding has an all-round grinding effect on the passivation layer formed by electrochemical processing, and the processing efficiency and processing effect have been greatly improved. At the same time, for the inner wall of the pipe that is not very good at the rolling grinding process, the electrochemical part also has a good processing effect. However, this patent cannot polish capillary tubes with a large length-to-diameter ratio and metal tubes with complex shapes, and there is room for further improvement in the expansion of part types and performance. Summary of the Invention

[0008] In order to overcome the deficiencies of the existing technology, such as difficult polishing of complex flow channels, slender pipes and inner walls of small holes, low polishing efficiency and unstable material removal, the present invention provides an electrochemical gradient thickening-ultrasonic shear composite rheological manufacturing method and device, which can not only greatly improve the polishing efficiency, but also achieve atomic near-atomic scale polishing accuracy.

[0009] The technical solution adopted by the present invention to solve its technical problems is:

[0010] An electrochemically gradient thickening-ultrasonic shearing composite rheological manufacturing method uses an electrochemical interface reaction to dissolve the anode surface of a workpiece and form a passivation film, and thermosensitive particles induce an aggregation effect of nano-abrasives in a suspension, and then uses a flexible ultrasonic fluid abrasive tool to shear and remove materials.

[0011] Furthermore, the electrochemically gradient thickening-ultrasonic shearing composite rheological manufacturing method includes the following steps:

[0012] (1) Place the workpiece on the machine tool workbench, clamp the anode on the anode workpiece, and clamp the cathode on the cathode connecting piece;

[0013] (2) Clamp the connecting nozzle at the liquid inlet of the anode workpiece along the cooling system and the constant temperature chamber channel;

[0014] (3) Add the electrochemically gradient thickening polishing liquid containing nano-abrasives to the electrochemically gradient thickening polishing liquid tank, turn on the hydraulic pump, and the electrochemically gradient thickening polishing liquid flows into the inner cavity of the workpiece along the liquid delivery pipe, telescopic pipe, etc.;

[0015] (4) Turn on the power supply and adjust the transformer so that an electrochemical reaction occurs on the inner surface of the workpiece, causing the anode surface of the workpiece to dissolve and form a passivation film;

[0016] (5) Turn on the ultrasonic signal generator, the signal is transmitted by the ultrasonic signal transmission line, and ultrasonic waves are focused into the rotating polishing shaft through the ultrasonic transducer and the horn;

[0017] (6) Turn on the temperature controller and adjust the temperature. At this time, the thermosensitive particles control the aggregation of nano-abrasives in the suspension to form a timely weakly rigid flexible ultrasonic fluid abrasive tool, and the flexible ultrasonic fluid abrasive tool efficiently shears and removes materials under hydraulic pressure.

[0018] In the step (3), the nano-abrasives include nano-diamond, cubic boron nitride, boron carbide, silicon carbide, silicon nitride, silicon oxide, gallium oxide, iron oxide, magnesium oxide, lithium fluoride, graphite or Al 2 O 3 or a mixture of one or more of them.

[0019] In the step (6), the thermosensitive particles are NIPAMODA, that is, a copolymer of N-isopropylacrylamide (NIPAM) and octadecyl acrylate (ODA), polyurethane, polynorbornene or styrene-butadiene copolymer, etc.

[0020] In the step (3), the electrochemically gradient thickening polishing liquid is an acidic, neutral or alkaline polishing liquid.

[0021] Preferably, an acidic electrochemical gradient thickening polishing liquid is used for processing titanium alloy materials and stainless steel materials, including an electrochemical gradient thickening polishing liquid composed of a phosphoric acid system, a sulfuric acid system, a perchloric acid system, a phosphoric acid-sulfuric acid system and various additives; the acidic polishing liquid with better versatility is a phosphoric acid-sulfuric acid system electrochemical gradient thickening polishing liquid, and the additives include corrosion inhibitors, leveling agents and brighteners. The corrosion inhibitors include ethanol, butanol, ethylene glycol, acetic acid or oxalic acid, etc. The leveling agents include triethanolamine, urea or thiourea, etc. The brighteners include glucose, saccharin, starch or sucrose, etc.

[0022] An electrochemical gradient thickening-ultrasonic shearing composite rheological manufacturing device includes an ultrasonic assistance device, a power supply assistance device, an electrochemical gradient thickening polishing liquid circulation assistance device, a temperature control device and a polishing device. The ultrasonic assistance device is located at the upper end of the box body; the power supply assistance device is located at the lower left end of the box body; the electrochemical gradient thickening polishing liquid circulation assistance device is located at the right end of the box body; the temperature control device is located in the middle of the box body; the polishing device is located inside the box body; the polishing device includes a cathode connector, a telescopic tube, a connecting nozzle, a fixture, an adjusting gasket, an anode workpiece and a machine tool workbench. The upper end of the telescopic tube is connected to the liquid outlet of the electrochemical gradient thickening polishing liquid circulation assistance device through the cathode connector. There is an adjusting gasket between the box body and the telescopic tube. The telescopic tube is connected to the anode workpiece through the connecting nozzle. The lower end of the anode workpiece is fixed on the machine tool workbench.

[0023] The ultrasonic assistance device includes, from top to bottom, an ultrasonic signal generator, an ultrasonic signal transmission line, an ultrasonic transducer, a heat sink and a horn. The ultrasonic signal generator is connected to the ultrasonic transducer through the ultrasonic signal transmission line. The ultrasonic transducer is wrapped by the heat sink. The lower end of the ultrasonic transducer is connected to the horn, and the lower end of the horn is at the confluence of two liquid delivery tubes.

[0024] The power supply assistance device includes a DC power supply, a circuit protection component, a transformer, an anode clamp, a cathode clamp, a voltmeter and an ammeter. The power supply assistance device is located at the left end of the box body. The anode of the power supply is connected to the anode workpiece through the circuit protection component. The cathode of the power supply is connected to the cathode connector through the transformer. The voltmeter is used to measure the output voltage, and the ammeter is used to measure the output current.

[0025] The electrochemical gradient thickening polishing liquid circulation assistance device includes a liquid delivery tube, a hydraulic pump, a filter, an electrochemical gradient thickening polishing liquid tank and a drain port. The electrochemical gradient thickening polishing liquid circulation assistance device is located at the right end of the box body. The electrochemical gradient thickening polishing liquid flows through the filter, the hydraulic pump and the ultrasonic assistance device in sequence through the liquid delivery tube to reach the inner cavity of the workpiece, and then flows back to the electrochemical gradient thickening polishing liquid tank through the drain port to complete the circulation of the electrochemical gradient polishing liquid.

[0026] The temperature control device described above includes a cooling system, a constant temperature chamber, a heating plate, a temperature controller, and a cooling pad. The temperature control device is located in the middle of the box body. The cooling system is at the upper end of the constant temperature chamber. Heating plates are provided on the inner walls on both sides of the constant temperature chamber, and a cooling pad is placed at the lower end. The temperature controller is at the outer end of the constant temperature chamber.

[0027] The cooling pad described above is made of an insulating material and is in the shape of a slope. After the electrochemically gradient thickened polishing liquid flows onto the cooling pad after polishing, its temperature rapidly decreases, enhancing the fluidity of the electrochemically gradient thickened polishing liquid, and flowing into the drain port along the direction of the cooling pad.

[0028] The ultrasonic transducer described above uses a giant magnetostrictive material, which has the advantages of greater energy density, higher conversion efficiency, and faster response speed compared to traditional materials.

[0029] The cathode connector described above is made of a metal conductive material, which can not only play a connecting role but also provide current for the electrochemically gradient thickened polishing liquid.

[0030] The filter described above is divided into physical filtration and chemical filtration. Physical filtration mainly filters out the passivation film and workpiece debris in the electrochemically gradient thickened polishing liquid, and chemical filtration removes the metal cations in the electrochemically gradient thickened polishing liquid.

[0031] The beneficial effects of the present invention are mainly manifested in:

[0032] 1) Stable material removal. The electrochemically gradient thickening involved in the present invention can achieve the weak rigid stability of the fluid abrasive tool in a specific temperature range. Compared with traditional non-Newtonian fluid polishing, it greatly improves the stable removal of materials and improves the surface accuracy.

[0033] 2) The important role of ultrasonic waves. Ultrasonic waves not only promote and physically strengthen the electrochemical process (mainly manifested as strengthening the diffusion mass transfer process in electrochemical polishing), accelerating the redox speed on the electrode surface, but also can assist the nano-abrasives to efficiently shear and remove the surface of the anode workpiece.

[0034] 3) Easy chip removal. Chips will be generated during the polishing process, which will affect the surface machining accuracy through continuous accumulation. The present invention uses abrasive flow rheology technology to remove chips. During the processing, the polishing liquid can effectively remove the chips in a timely manner, keeping the surface of the workpiece clean, thus ensuring the progress of polishing.

[0035] 4) Fast heat dissipation. The workpiece and the removal tool remove materials by mutual friction, and a large amount of heat will be generated during the removal process, which will affect the surface polishing accuracy of the workpiece and cause burn problems on the surface of the workpiece. The present invention uses the cavitation effect, which can not only accelerate the mechanical damage to the surface of the workpiece but also fully play the role of cooling and lubrication, thus reducing or avoiding the burn problems caused by traditional polishing to the surface of the workpiece.

[0036] 5) Higher material removal. The electro-chemical ultrasonic shear rheological polishing technology adopted by the present invention is specifically as follows: after power-on, under the action of electro-chemical reaction, a large number of protrusions on the anode surface of the workpiece are dissolved first and a passivation film is formed; under the action of the temperature control device, the thermosensitive particles control the aggregation of nano-abrasives in the suspension to form a timely weakly rigid flexible ultrasonic fluid abrasive tool, and under the hydraulic push, the flexible ultrasonic fluid abrasive tool efficiently shears and removes materials, thus realizing a new method of electro-chemical gradient thickening - ultrasonic shear composite rheological manufacturing.

[0037] 6) The present invention has relatively low requirements for polishing equipment. Description of the Drawings

[0038] Figure 1 Schematic diagram of an electro-chemical gradient thickening - ultrasonic shear composite rheological manufacturing device.

[0039] Figure 2 Schematic diagram of an electro-chemical gradient thickening - ultrasonic shear composite rheological manufacturing component (workpiece and fixture not marked).

[0040] Figure 3 Schematic diagram of the internal flow channel, where (a) represents a single flow channel and (b) represents a multi-flow channel.

[0041] Figure 4 Schematic diagram of the polishing method of an electro-chemical gradient thickening - ultrasonic shear composite rheological manufacturing device (a part of the internal flow channel is intercepted).

[0042] Figure 5 Schematic diagram of the microscopic view of abrasive grain shearing and removing materials (a part of the internal flow channel is intercepted).

[0043] Among them, 1. Box body; 2. Ultrasonic signal generator; 3. Ultrasonic signal transmission line; 4. Ultrasonic transducer; 5. Heat sink; 6. Amplitude transformer; 7. Liquid delivery pipe; 8. Hydraulic pump; 9. Filter; 10. Drain port; 11. Electro-chemical gradient thickening polishing liquid tank; 12. Circuit protection component; 13. DC power supply; 14. Transformer; 15. Voltmeter; 16. Cooling pad; 17. Ammeter; 18. Machine tool workbench; 19. Fixture; 20. Anode workpiece; 21. Heating plate; 22. Constant temperature chamber; 23. Cooling system; 24. Connecting nozzle; 25. Adjusting gasket; 26. Telescopic tube; 27. Cathode connecting piece; 28. Thermosensitive particle; 29. Nano-abrasive; 30. Ultrasonic wave; 31. Cavitation bubble; 32. Aggregation effect; 33. Hydraulic pressure; 34. Electro-chemical reaction; 35. Abrasive grain shearing and removing passivation film; 36. After multiple composite processing; 37. Anodic dissolution; 38. Passivation film; 39. Abrasive grain shearing. Detailed Embodiment

[0044] The present invention will be further described below in conjunction with the drawings.

[0045] Referring to Figures 1 to 5 , an electrochemically gradient thickening-ultrasonic shearing composite rheological manufacturing method uses an electrochemical interface reaction to dissolve the anode surface of a workpiece and form a passivation film. The thermosensitive particles 28 induce the aggregation effect of nano-abrasives in the suspension, and then a flexible ultrasonic fluid abrasive tool is used to shear and remove materials. This method can not only greatly improve the polishing efficiency but also achieve atomic-scale polishing accuracy.

[0046] An electrochemically gradient thickening-ultrasonic shearing composite rheological manufacturing device includes an ultrasonic assistance device, a power supply assistance device, an electrochemically gradient thickening polishing liquid circulation assistance device, a temperature control device, and a polishing device. The ultrasonic assistance device successively includes an ultrasonic signal generator 2, an ultrasonic signal transmission line 3, an ultrasonic transducer 4, a heat sink 5, and a horn 6 from top to bottom. The ultrasonic assistance device is located at the upper end of the box body 1. The power supply assistance device includes a DC power supply 13, a circuit protection component 12, a transformer 14, an anode clamp 40, a cathode clamp 41, a voltmeter 15, and an ammeter 17. The power supply assistance device is located at the lower left end of the box body 1. The electrochemically gradient thickening polishing liquid circulation assistance device includes an infusion tube 7, a hydraulic pump 8, a filter 9, an electrochemically gradient thickening polishing liquid tank 11, and a drain port 10. The electrochemically gradient thickening polishing liquid circulation assistance device is located at the right end of the box body 1. The temperature control device includes a cooling system 23, a constant temperature chamber 22, a heating plate 21, a temperature controller 42, and a cooling pad 16. The temperature control device is located in the middle of the box body 1. The polishing device includes a cathode connector 27, a telescopic tube 26, a connecting nozzle 24, a fixture 19, an adjusting gasket 25, an anode workpiece 20, and a machine tool workbench 18. The polishing device is located inside the box body 1.

[0047] The ultrasonic assistance device includes an ultrasonic signal generator 2, an ultrasonic signal transmission line 3, an ultrasonic transducer 4, a heat sink 5, and a horn 6. The ultrasonic signal generator 2 is connected to the ultrasonic transducer 4 through the ultrasonic signal transmission line 3. The ultrasonic transducer 4 is wrapped by the heat sink 5. The lower end of the ultrasonic transducer 4 is connected to the horn 6. The lower end of the horn 6 is located at the convergence of the two infusion tubes 7.

[0048] The ultrasonic transducer 4 is made of giant magnetostrictive material, which has the advantages of greater energy density, higher conversion efficiency, and faster response speed compared with traditional materials. At ultrasonic frequencies, the transducer made of giant magnetostrictive material has a serious heating phenomenon, and heat sinks 5 are arranged around it to relieve the overheating of the transducer to a certain extent.

[0049] The described power supply auxiliary device includes a DC power supply 13, a circuit protection component 12, a transformer 14, a voltmeter 15, and an ammeter 17. The power supply auxiliary device is located at the left end of the box body 1. The anode of the power supply is connected to the anode workpiece 20 through the circuit protection component 12, and the cathode of the power supply is connected to the cathode connector 27 through the transformer 14. The voltage measured by the voltmeter 15 is the output voltage, and the current measured by the ammeter 17 is the output current.

[0050] The described DC power supply 13 is a silicon rectifier power supply and a thyristor rectifier power supply. Optionally, the circuit protection component 12 effectively prevents damage caused by circuit short - circuit or excessive electrical load.

[0051] The described electrochemical gradient thickening polishing fluid circulation auxiliary device includes an infusion tube 7, a hydraulic pump 8, a filter 9, an electrochemical gradient thickening polishing fluid tank 11, and a drain port 10. The electrochemical gradient thickening polishing fluid circulation auxiliary device is located at the right end of the box body 1. The electrochemical gradient thickening polishing fluid flows through the filter 9, the hydraulic pump 8, and the ultrasonic auxiliary device in sequence through the infusion tube 7 to reach the inner cavity of the workpiece, and then flows back to the electrochemical gradient thickening polishing fluid tank through the drain port 10 to complete the circulation of the electrochemical gradient polishing fluid.

[0052] The described filter 9 is divided into physical filtration and chemical filtration. Physical filtration mainly filters out the passivation film and workpiece debris in the electrochemical gradient thickening polishing fluid, and chemical filtration removes the metal cations in the electrochemical gradient thickening polishing fluid.

[0053] The electrochemical gradient thickening polishing fluid contains nano - abrasive grains 29. The nano - abrasive grains 29 include nano - diamond, cubic boron nitride, boron carbide, silicon carbide, silicon nitride, silicon oxide, gallium oxide, iron oxide, magnesium oxide, lithium fluoride, graphite, or Al 2 O 3 or a mixture of one or more of them.

[0054] The described electrochemical gradient thickening polishing fluid usually includes acidic, neutral, and alkaline polishing fluids. For processing titanium alloy materials and stainless steel materials, acidic electrochemical gradient thickening polishing fluids are mainly used, including those composed of phosphoric acid - based, sulfuric acid - based, perchloric acid - based, phosphoric acid - sulfuric acid - based, and various additives. The acidic polishing fluid with better versatility is the phosphoric acid - sulfuric acid - based electrochemical gradient thickening polishing fluid. The additives mainly include corrosion inhibitors, leveling agents, and brightening agents. Among them, the corrosion inhibitors include ethanol, butanol, ethylene glycol, acetic acid, or oxalic acid, etc.; the leveling agents include triethanolamine, urea, or thiourea, etc.; and the brightening agents include glucose - based, saccharin, starch, or sucrose - based, etc.

[0055] The described thermosensitive particles 28 are NIPAMODA, that is, a copolymer of N - isopropylacrylamide (NIPAM) and octadecyl acrylate (ODA), polyurethane, polynorbornene, or styrene - butadiene copolymer, etc.

[0056] The components and formulation of the phosphoric acid-sulfuric acid-based electrochemical gradient thickening polishing liquid are as follows: In ultrapure water at 25°C, nano-abrasives, pH adjusters, corrosion inhibitors, leveling agents, brightening agents, and thermosensitive particles are added to prepare a polishing processing suspension. Among them, the mass fraction of the nano-abrasives is between 8% and 20%, the mass fraction of the pH adjuster is between 0.05% and 1.0%, the mass fractions of the corrosion inhibitor, leveling agent, and brightening agent are all between 0.05% and 1.0%, and the mass fraction of the thermosensitive particles is between 2% and 10%.

[0057] The temperature control device described above includes a cooling system 23, a constant temperature chamber 22, a heating plate 21, a temperature controller 42, and a cooling pad 16. The temperature control device is located in the middle of the box body 1; the cooling system 23 is at the upper end of the constant temperature chamber 22, heating plates 21 are provided on the inner walls on both sides of the constant temperature chamber 22, and the cooling pad 16 is placed at the lower end. The temperature controller 42 is at the outer end of the constant temperature chamber 22.

[0058] The constant temperature chamber 22 is provided with a heating plate 21. When the temperature reaches a certain range, the thermosensitive particles 28 in the electrochemical gradient thickening polishing liquid control the aggregation of nano-abrasives in the suspension to form a timely weakly rigid flexible ultrasonic fluid abrasive tool; in addition, it can also achieve a constant temperature effect. The cooling system 23 described above can play a role in rapid cooling. Before the electrochemical gradient thickening polishing liquid enters the anode workpiece 20, the fluidity of the polishing liquid is strong, which is convenient for it to enter the anode workpiece 20. The cooling pad 16 is made of an insulating material and is in the shape of a slope. After the electrochemical gradient thickening polishing liquid after polishing flows to the cooling pad 16, its temperature drops rapidly, increasing the fluidity of the electrochemical gradient thickening polishing liquid, and flowing into the drain port 10 along the direction of the cooling pad 16.

[0059] The polishing device described above includes a cathode connector 27, a telescopic tube 26, a connecting nozzle 24, a fixture 19, an adjusting gasket 25, an anode workpiece 20, and a machine tool workbench 18. The polishing device is located inside the box body 1. The upper end of the telescopic tube 26 is connected to the outlet of the infusion tube 7 through the cathode connector 27. An adjusting gasket 25 is provided between the box body 1 and the telescopic tube 26. The telescopic tube 26 is connected to the anode workpiece 20 through the connecting nozzle 24. The lower end of the anode workpiece 20 is fixed on the machine tool workbench 18.

[0060] The cathode connector 27 is made of a metal conductive material, which can not only play a connecting role but also provide current for the electrochemical gradient thickening polishing liquid. The anode workpiece is a component with complex structures such as internal flow channels (single-channel, multi-channel), cavities, etc. of high-energy beam laser additive manufactured products, slender capillary tubes, and standard parts tubes. Its material is mainly titanium alloy materials and stainless steel materials. Among them, the titanium alloy materials include Ti-6Al-4V, Ti-6Al-2Sn-4Zr-6Mo, etc., and the stainless steel materials include 304, 316L, 17-4PH, etc.

[0061] An electrochemically gradient thickening-ultrasonic shearing composite rheological manufacturing method uses an electrochemical interface reaction to dissolve the anode surface of a workpiece and form a passivation film. Thermosensitive particles induce an aggregation effect of nano-abrasives in a suspension, and then a flexible ultrasonic fluid abrasive tool is used to shear and remove materials.

[0062] The electrochemically gradient thickening-ultrasonic shearing composite rheological manufacturing method includes the following steps:

[0063] (1) Place the workpiece on the machine tool workbench 18, clamp the anode clamp 40 on the anode workpiece 20, and clamp the cathode clamp 41 on the cathode connecting member 27;

[0064] (2) Clamp the connecting nozzle 24 at the liquid inlet of the anode workpiece 20 along the channels of the cooling system 23 and the constant temperature chamber 22;

[0065] (3) Add the electrochemically gradient thickening polishing liquid containing nano-abrasives 29 to the electrochemically gradient thickening polishing liquid tank 11, turn on the hydraulic pump 8, and the electrochemically gradient thickening polishing liquid flows into the inner cavity of the workpiece along the liquid delivery pipe 7, the telescopic pipe 26, etc.;

[0066] (4) Turn on the power supply and adjust the transformer 14 so that an electrochemical reaction occurs on the inner surface of the workpiece, causing the anode surface of the workpiece to dissolve and form a passivation film;

[0067] (5) Turn on the ultrasonic signal generator 2, the signal is transmitted by the ultrasonic signal transmission line 3, and ultrasonic waves are focused into the rotating polishing shaft through the ultrasonic transducer 4 and the amplitude transformer 6;

[0068] (6) Turn on the temperature controller 42 and adjust the appropriate temperature. At this time, the thermosensitive particles 28 control the aggregation of nano-abrasives in the suspension to form a timely weakly rigid flexible ultrasonic fluid abrasive tool, and the flexible ultrasonic fluid abrasive tool efficiently shears and removes materials under the hydraulic push, thereby realizing the new method of electrochemically gradient thickening-ultrasonic shearing composite rheological manufacturing.

[0069] Example 1

[0070] The present invention is used to process an additive manufacturing slender tube with dimensions: an outer diameter of 2 mm, an inner diameter of 1 mm, and a length of 1000 mm (the material is mainly titanium alloy material and stainless steel material).

[0071] The electrochemically gradient thickening-ultrasonic shearing composite rheological manufacturing method includes the following steps:

[0072] (1) Place the additive manufacturing slender tube with an outer diameter of 2 mm, an inner diameter of 1 mm, and a length of 1000 mm on the machine tool workbench 18, clamp the anode clamp 40 on the anode workpiece 20, and clamp the cathode clamp 41 on the cathode connecting member 27;

[0073] (2) Clamp the connecting nozzle 24 along the channels of the cooling system 23 and the constant temperature chamber 22 at the liquid inlet of the additively manufactured slender tube.

[0074] (3) Add the electrochemically gradient thickened polishing liquid containing nano-abrasives 29 into the electrochemically gradient thickened polishing liquid tank 11, turn on the hydraulic pump 8, and the electrochemically gradient thickened polishing liquid flows into the inner cavity of the workpiece along the liquid delivery pipe 7, the telescopic pipe 26, etc.

[0075] (4) Turn on the power supply and adjust the transformer 14 to cause an electrochemical reaction on the inner surface of the workpiece, so that the anode surface of the workpiece dissolves and a passivation film is formed.

[0076] (5) Turn on the ultrasonic signal generator 2, the signal is transmitted by the ultrasonic signal transmission line 3, and ultrasonic waves are focused into the rotary polishing shaft through the ultrasonic transducer 4 and the horn 6.

[0077] (6) Turn on the temperature controller 42 and adjust to a suitable temperature. At this time, the thermosensitive particles 28 control the aggregation of nano-abrasives in the suspension to form a timely weakly rigid flexible ultrasonic fluid abrasive tool. Under the hydraulic push, the flexible ultrasonic fluid abrasive tool efficiently shears and removes materials, thus realizing a new method of electrochemically gradient thickened - ultrasonic shear composite rheological manufacturing.

[0078] Example 2

[0079] The present invention is used to process a stainless steel single flow channel with dimensions of 100 mm in length, 80 mm in width, and 60 mm in height.

[0080] The electrochemically gradient thickened - ultrasonic shear composite rheological manufacturing method includes the following steps:

[0081] (1) Place the stainless steel single flow channel with dimensions of 100 mm in length, 80 mm in width, and 60 mm in height on the machine tool workbench 18, clamp the anode clamp 40 on the anode workpiece 20, and clamp the cathode clamp 41 on the cathode connecting piece 27.

[0082] (2) Clamp the connecting nozzle 24 along the channels of the cooling system 23 and the constant temperature chamber 22 at the liquid inlet of the stainless steel single flow channel.

[0083] (3) Add the electrochemically gradient thickened polishing liquid containing nano-abrasives 29 into the electrochemically gradient thickened polishing liquid tank 11, turn on the hydraulic pump 8, and the electrochemically gradient thickened polishing liquid flows into the inner cavity of the workpiece along the liquid delivery pipe 7, the telescopic pipe 26, etc.

[0084] (4) Turn on the power supply and adjust the transformer 14 to cause an electrochemical reaction on the inner surface of the workpiece, so that the anode surface of the workpiece dissolves and a passivation film is formed.

[0085] (5) Turn on the ultrasonic signal generator 2. The signal is transmitted through the ultrasonic signal transmission line 3, and ultrasonic waves are focused into the rotary polishing shaft through the ultrasonic transducer 4 and the horn 6.

[0086] (6) Turn on the temperature controller 42 and adjust to an appropriate temperature. At this time, the thermosensitive particles 28 control the aggregation of nano-abrasives in the suspension to form a timely weakly rigid flexible ultrasonic fluid abrasive tool. Under the hydraulic drive, the flexible ultrasonic fluid abrasive tool efficiently shears and removes materials, thus realizing a new method of electrochemical gradient thickening-ultrasonic shear composite rheological manufacturing.

[0087] Example 3

[0088] The present invention is used to process a titanium alloy multi-channel with dimensions of 110 mm in length, 85 mm in width, and 60 mm in height.

[0089] The electrochemical gradient thickening-ultrasonic shear composite rheological manufacturing method includes the following steps:

[0090] (1) Place the titanium alloy multi-channel with dimensions of 110 mm in length, 85 mm in width, and 60 mm in height on the machine tool workbench 18. The anode clamp 40 is clamped on the anode workpiece 20, and the cathode clamp 41 is clamped on the cathode connecting member 27.

[0091] (2) Clamp the connecting nozzle 24 at the liquid inlet of the titanium alloy multi-channel along the channels of the cooling system 23 and the constant temperature chamber 22.

[0092] (3) Add the electrochemical gradient thickening polishing liquid containing nano-abrasives 29 into the electrochemical gradient thickening polishing liquid tank 11. Turn on the hydraulic pump 8, and the electrochemical gradient thickening polishing liquid flows into the inner cavity of the workpiece along the liquid delivery pipe 7, the telescopic pipe 26, etc.

[0093] (4) Turn on the power supply and adjust the transformer 14 so that an electrochemical reaction occurs on the inner surface of the workpiece, causing the anode surface of the workpiece to dissolve and form a passivation film.

[0094] (5) Turn on the ultrasonic signal generator 2. The signal is transmitted through the ultrasonic signal transmission line 3, and ultrasonic waves are focused into the rotary polishing shaft through the ultrasonic transducer 4 and the horn 6.

[0095] (6) Turn on the temperature controller 42 and adjust to an appropriate temperature. At this time, the thermosensitive particles 28 control the aggregation of nano-abrasives in the suspension to form a timely weakly rigid flexible ultrasonic fluid abrasive tool. Under the hydraulic drive, the flexible ultrasonic fluid abrasive tool efficiently shears and removes materials, thus realizing a new method of electrochemical gradient thickening-ultrasonic shear composite rheological manufacturing.

[0096] The content described in the embodiments of this specification is only an enumeration of the implementation forms of the inventive concept and is for illustrative purposes only. The protection scope of the present invention should not be regarded as limited to the specific forms stated in this embodiment, and the protection scope of the present invention also extends to equivalent technical means that can be conceived by those of ordinary skill in the art based on the inventive concept of the present invention.

Claims

1. An electrochemical gradient thickening-ultrasonic shearing composite rheological manufacturing method, characterized in that: The electrochemical interface reaction is used to dissolve the anode surface of the workpiece and form a passivation film. The thermosensitive particles induce the nano-abrasive particles in the suspension to produce an aggregation effect, and then the flexible ultrasonic fluid abrasive tool is used to shear and remove the material.

2. The electrochemical gradient thickening-ultrasonic shearing composite rheological manufacturing method according to claim 1, characterized in that: The method comprises the following steps: (1) Place the workpiece on the machine tool workbench, clamp the anode clamp on the anode workpiece, and clamp the cathode clamp on the cathode connector; (2) Clamp the connecting nozzle at the liquid inlet of the anode workpiece along the cooling system and the constant temperature chamber channel; (3) adding the electrochemical gradient thickened polishing liquid containing nano-abrasive particles into the electrochemical gradient thickened polishing liquid tank, turning on the hydraulic pump, and allowing the electrochemical gradient thickened polishing liquid to flow into the inner cavity of the workpiece along the infusion tube, the telescopic tube, etc.; (4) Turn on the power supply and adjust the transformer so that an electrochemical reaction occurs on the inner surface of the workpiece, causing the anode surface of the workpiece to dissolve and form a passivation film; (5) Turn on the ultrasonic signal generator, the signal is transmitted by the ultrasonic signal transmission line, and the ultrasonic wave is focused into the rotating polishing shaft through the ultrasonic transducer and the horn; (6) Turn on the temperature controller and adjust the temperature. At this time, the thermosensitive particles control the aggregation of nano-abrasive particles in the suspension to form a timely weak rigid flexible ultrasonic fluid abrasive. Under the hydraulic pressure, the flexible ultrasonic fluid abrasive can efficiently shear and remove materials.

3. The electrochemical gradient thickening-ultrasonic shearing composite rheological manufacturing method according to claim 2, characterized in that: In the step (3), the nano-abrasive particles include one or a mixture of two or more of nano-diamond, cubic boron oxide, boron carbide, silicon carbide, silicon nitride, silicon oxide, gallium oxide, iron oxide, magnesium oxide, lithium fluoride, graphite or Al2O3.

4. The electrochemical gradient thickening-ultrasonic shearing composite rheological manufacturing method according to claim 2, characterized in that: In the step (6), the heat-sensitive particles are NIPAMODA, i.e., a copolymer of N-isopropylacrylamide (NIPAM) and octadecyl acrylate (ODA), polyurethane, polynorbornene or styrene-butadiene copolymer.

5. The electrochemical gradient thickening-ultrasonic shearing composite rheological manufacturing method according to claim 4, characterized in that: In the step (3), the electrochemical gradient thickened polishing liquid is an acidic, neutral or alkaline polishing liquid; for processing titanium alloy materials and stainless steel materials, an acidic electrochemical gradient thickened polishing liquid is used, which includes an electrochemical gradient thickened polishing liquid composed of phosphoric acid, sulfuric acid, perchloric acid, phosphoric acid-sulfuric acid and various additives; the acidic polishing liquid with better versatility is a phosphoric acid-sulfuric acid electrochemical gradient thickened polishing liquid, wherein the additives include corrosion inhibitors, leveling agents and brighteners, wherein the corrosion inhibitors include ethanol, butanol, ethylene glycol, acetic acid or oxalic acid, etc., the leveling agents include triethanolamine, urea or thiourea, etc., and the brighteners include glucose, saccharin, starch or sucrose, etc.

6. A device for implementing the electrochemical gradient thickening-ultrasonic shearing composite rheological manufacturing method as claimed in claim 1, characterized in that: The device includes an ultrasonic auxiliary device, a power supply auxiliary device, an electrochemical gradient thickening polishing liquid circulation auxiliary device, a temperature control device and a polishing device. The ultrasonic auxiliary device is located at the upper end of the box; the power supply auxiliary device is located at the lower left end of the box; the electrochemical gradient thickening polishing liquid circulation auxiliary device is located at the right end of the box; the temperature control device is located in the middle of the box; the polishing device is located inside the box; the polishing device includes a cathode connector, a telescopic tube, a connecting nozzle, a clamp, an adjustment gasket, an anode workpiece and a machine tool workbench. The upper end of the telescopic tube is connected to the infusion pipe outlet of the electrochemical gradient thickening polishing liquid circulation auxiliary device through the cathode connector. An adjustment gasket is provided between the box and the telescopic tube. The telescopic tube is connected to the anode workpiece through the connecting nozzle, and the lower end of the anode workpiece is fixed on the machine tool workbench.

7. The device according to claim 6, characterized in that The ultrasonic auxiliary device includes an ultrasonic signal generator, an ultrasonic signal transmission line, an ultrasonic transducer, a heat sink and a horn from top to bottom. The ultrasonic signal generator is connected to the ultrasonic transducer through the ultrasonic signal transmission line, the ultrasonic transducer is wrapped by the heat sink, the lower end of the ultrasonic transducer is connected to the horn, and the lower end of the horn is located at the confluence of two infusion tubes.

8. The device according to claim 6 or 7, characterized in that The power supply auxiliary device includes a DC power supply, a circuit protection component, a transformer, an anode clamp, a cathode clamp, a voltmeter and an ammeter. The power supply auxiliary device is located at the left end of the box. The anode of the power supply is connected to the anode workpiece through the circuit protection component, and the cathode of the power supply is connected through the transformer cathode connector. The voltmeter is used to measure the output voltage, and the ammeter is used to measure the output current.

9. The device according to claim 6 or 7, characterized in that The electrochemical gradient thickened polishing liquid circulation auxiliary device includes an infusion tube, a hydraulic pump, a filter, an electrochemical gradient thickened polishing liquid tank and a drain port. The electrochemical gradient thickened polishing liquid circulation auxiliary device is located at the right end of the box body. The electrochemical gradient thickened polishing liquid flows through the infusion tube through the filter, the hydraulic pump, and the ultrasonic auxiliary device in sequence to reach the inner cavity of the workpiece, and then flows back to the electrochemical gradient thickened polishing liquid tank through the drain port to complete the electrochemical gradient polishing liquid circulation.

10. The temperature control device described in the device as described in claim 6 or 7 includes a cooling system, a constant temperature chamber, a heating plate, a temperature controller and a cooling pad, and the temperature control device is located in the middle of the box; the cooling system is at the upper end of the constant temperature chamber, heating plates are provided on the inner walls of both sides of the constant temperature chamber, an oil cooling pad is placed at the lower end, and the temperature controller is at the outer end of the constant temperature chamber.

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