A multi-channel atomized ablation-electrolysis-chemical combined machining device and a method of using the same
By using a multi-channel atomization-electrolysis-chemical composite processing device, which utilizes multi-channel discharge to disperse energy and combines atomization atomization, electrolysis, and chemical reactions, the forming accuracy and quality problems of difficult-to-process materials are solved, achieving efficient and low-cost processing results.
Patent Information
- Application Number
- CN202611519070.7
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2026-09-29
- Publication Date
- 2026-11-06
AI Technical Summary
Traditional machining methods struggle to balance the forming accuracy and machining quality of difficult-to-machine materials such as titanium alloys, high-temperature alloys, and high-strength steel, resulting in problems such as high cutting forces, severe tool wear, low machining efficiency, and high costs.
A multi-channel atomization ablation-electrolysis-chemical composite processing device is adopted. By dispersing pulse energy through multi-channel discharge, and combining atomization ablation, electrolysis and chemical reaction, the material is efficiently removed. The oxidation combustion reaction is used to improve the material removal efficiency, the electrolysis removes the recast layer, and the chemical reaction improves the inter-electrode state.
It significantly improves the processing efficiency and surface quality of difficult-to-machine materials, reduces electrode wear, effectively removes the recast layer, shortens processing time, reduces costs, and is suitable for efficient processing of complex structures.
Smart Images
Figure CN123039487A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of electrical discharge machining technology, and in particular to a multi-channel atomization ablation-electrolysis-chemical composite machining apparatus and its usage method. Background Technology
[0002] Titanium alloys, high-temperature alloys, high-strength steels, and advanced composite materials possess characteristics such as high specific strength, high temperature resistance, and corrosion resistance. They are essential basic materials for key components in aerospace, shipbuilding, and biomedical fields, and their processing quality directly affects the service performance and reliability of equipment. As related components become increasingly complex, thin-walled, and integrated, traditional machining methods face challenges such as high cutting forces, severe tool wear, low processing efficiency, high manufacturing costs, and susceptibility to surface defects, making it difficult to balance forming accuracy and processing quality. Therefore, providing a machining method that can solve these problems has become a major research direction. Summary of the Invention
[0003] The purpose of this invention is to overcome the defects in the prior art and provide a multi-channel atomization ablation-electrolysis-chemical composite processing device and its usage method.
[0004] To achieve the above-mentioned objectives, the present invention provides the following technical solution: This invention provides a multi-channel atomization ablation-electrolysis-chemical composite processing device, the multi-channel atomization ablation-electrolysis-chemical composite processing device comprising: Pulse power supply, multi-channel electrode, gas cylinder, atomizing nozzle and electrolyte storage tank.
[0005] Preferably, the multi-channel electrode is connected in series with the negative terminal of the pulse power supply.
[0006] Preferably, the multi-channel electrode is composed of sub-electrodes; The number of sub-electrodes is 4 to 6; the outer diameter of each sub-electrode is 8 to 12 mm, and the inner diameter is 5 to 7 mm; The sub-electrodes are connected in parallel; the surface of the sub-electrodes is provided with an insulating coating.
[0007] As a preferred embodiment, each sub-electrode is independently connected in series with a fixed resistor; The resistance of the fixed resistor is 4~6Ω.
[0008] Preferably, each sub-electrode is provided with a dielectric inflow end and a discharge end; The gas cylinder and electrolyte storage tank are respectively connected to the atomizing nozzle; The atomizing nozzle is connected to the medium inflow end of the sub-electrode.
[0009] The present invention also provides a method of using the multi-channel atomization ablation-electrolysis-chemical composite processing device, comprising the following steps: (1) The atomized medium formed by the oxygen in the gas cylinder and the electrolyte in the electrolyte storage tank is transported to the processing area through a multi-channel electrode, and the multi-channel electrode is connected to the negative terminal of the pulse power supply. (2) Connect the positive terminal of the pulse power supply to the workpiece for processing.
[0010] Preferably, the pressure of the atomizing medium in step (1) is 0.01~3MPa.
[0011] Preferably, the solute in the electrolyte in step (1) is one or more of Na2CO3, NaNO3 and NaCl.
[0012] Preferably, the concentration of the electrolyte in step (1) is 0.5~2.5wt%.
[0013] Preferably, the material of the workpiece in step (2) is a conductive material.
[0014] This invention provides a multi-channel atomization-electrolysis-chemical composite processing device, comprising: a pulse power supply, a multi-channel electrode, a gas cylinder, an atomizing nozzle, and an electrolyte storage tank. The multi-channel electrode is connected in series with the negative terminal of the pulse power supply. The multi-channel electrode is composed of sub-electrodes. The gas cylinder and the electrolyte storage tank are respectively connected to the atomizing nozzle; the atomizing nozzle is connected to the medium inflow end of the sub-electrode. The multi-channel electrode is composed of parallel combinations of mutually insulated sub-electrodes. Each sub-electrode has a medium inflow end and a discharge end, and is connected in series with a fixed resistor to achieve multi-channel discharge within a single pulse cycle. Multi-channel discharge, by dispersing the pulse energy, reduces the energy density of a single channel compared to single-channel discharge, reducing electrode wear and improving surface quality. During the processing, a gas-liquid atomized medium formed by oxygen and electrolyte is delivered to the processing area through a multi-channel electrode. The oxidation-combustion reaction of atomized ablation improves the material removal efficiency, while the weak electrolysis generated during the pulse interval removes the recast layer formed on the material surface. Furthermore, the chemical reaction between the electrolyte and the processed product improves the inter-electrode state, ultimately achieving a combined processing effect of electrical discharge machining (EDM) and electrolysis. This invention targets a multi-channel atomized ablation-electrolysis-chemical composite processing method. The synergistic effect of the electrolysis generated by the electrolyte during the pulse interval and the multi-channel discharge significantly improves pulse utilization and material removal rate compared to traditional EDM or electrolytic machining, reduces relative electrode wear rate, and eliminates the recast layer formed on the workpiece surface after EDM, significantly improving material processing efficiency and surface quality.
[0015] The processing apparatus and method provided by this invention utilize the chemical energy released by atomized ablation to improve the material removal efficiency, employ multi-channel discharge to disperse pulse energy, reduce the thermal shock caused by intense ablation combustion, and improve surface quality, utilize the weak electrolysis generated during the pulse interval to remove the recast layer and reduce cathode electrode loss, and utilize the chemical reaction between the electrolyte and the processed product to improve the inter-electrode state, ultimately achieving a composite processing effect that significantly improves the material processing efficiency and surface quality. Furthermore, this method belongs to macroscopic non-cutting force machining, is not limited by the hardness, strength, or other mechanical properties of the metal material, and ensures that there is no residual stress on the processed surface.
[0016] Compared with traditional electrical discharge machining (EDM), this invention enables continuous, stable, and efficient machining of difficult-to-machine materials and effectively eliminates the recast layer on the machined surface. Under the same electrical parameters, its machining efficiency is significantly improved, thereby effectively shortening the machining time. Especially in the machining of difficult-to-machine metal materials such as titanium alloys, high-temperature alloys, and high-strength steel, this invention can effectively solve problems such as low machining efficiency, poor surface quality, and difficulty in removing the recast layer, reducing machining costs and further expanding the application scope of this technology. Attached Figure Description
[0017] Figure 1 This is a schematic diagram of the multi-channel atomization ablation-electrolysis-chemical composite processing device in Example 1; Figure 2 This is a microscopic schematic diagram of the multi-channel atomization ablation-electrolysis-chemical composite processing mechanism of the present invention. Detailed Implementation
[0018] This invention provides a multi-channel atomization ablation-electrolysis-chemical composite processing device, the multi-channel atomization ablation-electrolysis-chemical composite processing device comprising: Pulse power supply, multi-channel electrode, gas cylinder, atomizing nozzle and electrolyte storage tank.
[0019] In this invention, the multi-channel electrode is connected in series with the negative terminal of the pulse power supply.
[0020] In this invention, the multi-channel electrode is composed of sub-electrodes.
[0021] In this invention, the number of sub-electrodes is preferably 4 to 6, more preferably 5; the outer diameter of each sub-electrode is preferably 8 to 12 mm, further preferably 9 to 11 mm, more preferably 10 mm; the inner diameter is preferably 5 to 7 mm, further preferably 5.5 to 6.5 mm, more preferably 5.8 to 6.2 mm.
[0022] In this invention, the sub-electrodes are connected in parallel; the surface of the sub-electrodes is provided with an insulating coating.
[0023] In this invention, each sub-electrode is independently connected in series with a fixed resistor.
[0024] In this invention, the resistance value of the fixed resistor is preferably 4~6Ω, more preferably 4.5~5.5Ω, and even more preferably 4.8~5.2Ω.
[0025] In this invention, each sub-electrode is provided with a dielectric inflow end and a discharge end.
[0026] In this invention, the gas cylinder and the electrolyte storage tank are respectively connected to the atomizing nozzle; the oxygen in the gas cylinder is introduced into the atomizing nozzle to form a high-speed airflow, and pressurizes the electrolyte storage tank in another way to maintain a stable supply of gas and liquid phases.
[0027] In this invention, the atomizing nozzle is connected to the medium inflow end of the sub-electrode.
[0028] The present invention also provides a method of using the multi-channel atomization ablation-electrolysis-chemical composite processing device, comprising the following steps: (1) The atomized medium formed by the oxygen in the gas cylinder and the electrolyte in the electrolyte storage tank is transported to the processing area through a multi-channel electrode, and the multi-channel electrode is connected to the negative terminal of the pulse power supply. (2) Connect the positive terminal of the pulse power supply to the workpiece for processing.
[0029] In this invention, the pressure of the atomizing medium in step (1) is preferably 0.01~3MPa, more preferably 1~2MPa, and even more preferably 1.5~1.8MPa.
[0030] In this invention, the solute in the electrolyte in step (1) is one or more of Na2CO3, NaNO3 and NaCl.
[0031] In this invention, the concentration of the electrolyte in step (1) is preferably 0.5 to 2.5 wt%, more preferably 1 to 2 wt%, and even more preferably 1.4 to 1.6 wt%.
[0032] In this invention, the material of the workpiece in step (2) is a conductive material, preferably a titanium alloy, a high-temperature alloy, a high-strength steel or a composite material.
[0033] The technical solutions provided by the present invention will be described in detail below with reference to the embodiments, but they should not be construed as limiting the scope of protection of the present invention.
[0034] Example 1
[0035] The schematic diagram of the processing device in this embodiment is shown below. Figure 1 As shown, Figure 1In the diagram, 1 is the pulse power supply, 2 is the workpiece, 3 is the multi-channel electrode, 31 is the fixed resistor, 32 is the sub-electrode, 33 is the insulating coating, 4 is the gas cylinder, 5 is the atomizing nozzle, 6 is the electrolyte storage tank, and 7 is the pressure regulating valve.
[0036] Step 1: Prepare pulse power supply 1, workpiece 2, sub-electrode 32, insulating coating 33, fixed resistor 31, gas cylinder 4, atomizing nozzle 5, electrolyte storage tank 6, and pressure regulating valve 7.
[0037] Step 2: Spray an insulating coating onto the outer wall of the four sub-electrodes. Connect the insulated sub-electrodes in series with a fixed resistor. Combine all the sub-electrodes in parallel to form a multi-channel electrode. Connect the upper end of the multi-channel electrode to the outlet of the atomizing nozzle. Connect the gas cylinder and electrolyte to the pressure regulating valve and then to the air inlet and liquid inlet of the atomizing nozzle. Connect the positive terminal of the pulse power supply to the workpiece to be processed and the negative terminal to the multi-channel electrode.
[0038] Step 3: Open the gas cylinder and adjust the pressure regulating valve to continuously and stably spray the atomized medium formed by the mixture of electrolyte and oxygen from the center of the multi-channel electrode to the processing area. Turn on the pulse power supply and complete the machine tool tool setting preparation. Then, multi-channel atomization ablation-electrolysis-chemical composite high-efficiency processing can be performed on difficult-to-machine materials.
[0039] Specifically, the electrolyte is a 1.5 wt.% Na2CO3 solution, and the pressure of the atomizing medium is 1 MPa.
[0040] Specifically, the sub-electrode is a copper tube electrode with an outer diameter of 10mm and an inner diameter of 6mm, and an atomizing medium can be introduced into it.
[0041] The insulating coating is a 15μm polyurethane coating; the fixed resistor has a resistance of 5Ω; the machined parts are made of 9Cr18MoV high-strength steel.
[0042] When using multi-channel atomization ablation-electrolysis-chemical composite machining, the material removal rate of the workpiece is 247.12 mm. 3 The relative electrode wear rate was 4.52%, the workpiece surface roughness Ra was 2.30 μm, and the recast layer was completely removed; under the same electrical parameters, the material removal rate of the workpiece using conventional EDM was 30.71 mm. 3 The machining efficiency was 8 times higher than that of traditional electrical discharge machining (EDM), the relative electrode loss rate was 16.30%, the surface roughness Ra of the workpiece was 11.23 μm, and a recast layer with a thickness of approximately 17.4 μm remained on the workpiece surface after machining. Compared with traditional EDM, multi-channel atomization-electrolysis-chemical composite machining improved the machining efficiency by 8 times, reduced the relative electrode loss rate by 75%, reduced the surface roughness Ra to 1 / 5 of that of EDM, and could completely remove the recast layer formed after EDM.
[0043] A microscopic schematic diagram of the multi-channel atomization ablation-electrolysis-chemical composite processing mechanism of this invention is shown below. Figure 2 As shown, the microscopic mechanism is as follows: During pulsed discharge, the oxygen in the atomizing medium has a combustion-supporting effect, making the discharge more intense and enhancing the melting and ablation of the workpiece material. This creates a large activation and ablation zone on the substrate surface, while simultaneously causing the erosion products to form larger particles. After the discharge ends, the electrolyte in the atomizing medium reacts chemically with the erosion products, dissolving some of them and promoting the removal of processed products, thereby improving the inter-electrode processing environment. During the pulse interval, the electrolyte reacts electrolytically with the workpiece substrate, dissolving the oxide layer and recast layer formed on the workpiece surface, improving the workpiece surface condition.
[0044] The above process is continuously cycled with alternating pulsed discharge and intervals, achieving a synergistic effect of electrical spark atomization ablation and electrochemical dissolution, thereby improving material removal efficiency and processing surface quality.
[0045] This invention combines the advantages of multi-channel discharge, atomization ablation, electrolytic machining, and chemical reaction to achieve efficient and high-quality machining of difficult-to-machine materials. Multi-channel discharge disperses pulse energy, reducing the energy density of individual discharge channels and minimizing localized thermal damage. Atomization ablation utilizes the chemical energy released from oxidation and combustion to enhance material removal, significantly improving machining efficiency. Electrolysis removes residual recast layers from the machined surface. Chemical reaction eliminates non-conductive oxides generated between electrodes, improving inter-electrode conductivity and discharge stability. These mechanisms work synergistically to improve material removal rate and surface quality while effectively reducing electrode wear and the incidence of abnormal discharge. This method features a simple device structure, controllable process, high energy utilization, and low processing cost, making it particularly suitable for removing large quantities of difficult-to-machine materials and forming complex structures.
[0046] The above description is only a preferred embodiment of the present invention. It should be noted that for those skilled in the art, several improvements and modifications can be made without departing from the principle of the present invention, and these improvements and modifications should also be considered within the scope of protection of the present invention.
Claims
1. A multi-channel atomization ablation-electrolysis-chemical composite processing device, characterized in that, The multi-channel atomization ablation-electrolysis-chemical composite processing device includes: Pulse power supply, multi-channel electrode, gas cylinder, atomizing nozzle and electrolyte storage tank.
2. The multi-channel atomization ablation-electrolysis-chemical composite processing device as described in claim 1, characterized in that, The multi-channel electrode is connected in series with the negative terminal of the pulse power supply.
3. The multi-channel atomization ablation-electrolysis-chemical composite processing device as described in claim 2, characterized in that, The multi-channel electrode is composed of sub-electrodes; The number of sub-electrodes is 4 to 6; the outer diameter of each sub-electrode is 8 to 12 mm, and the inner diameter is 5 to 7 mm; The sub-electrodes are connected in parallel; the surface of the sub-electrodes is provided with an insulating coating.
4. The multi-channel atomization ablation-electrolysis-chemical composite processing device as described in claim 3, characterized in that, Each sub-electrode is independently connected in series with a fixed resistor; The resistance of the fixed resistor is 4~6Ω.
5. The multi-channel atomization ablation-electrolysis-chemical composite processing device as described in claim 4, characterized in that, Each sub-electrode is provided with a dielectric inflow end and a discharge end; The gas cylinder and electrolyte storage tank are respectively connected to the atomizing nozzle; The atomizing nozzle is connected to the medium inflow end of the sub-electrode.
6. The method of using the multi-channel atomization ablation-electrolysis-chemical composite processing device according to any one of claims 1 to 5, characterized in that, Includes the following steps: (1) The atomized medium formed by the oxygen in the gas cylinder and the electrolyte in the electrolyte storage tank is transported to the processing area through a multi-channel electrode, and the multi-channel electrode is connected to the negative terminal of the pulse power supply. (2) Connect the positive terminal of the pulse power supply to the workpiece for processing.
7. The method of using the multi-channel atomization ablation-electrolysis-chemical composite processing device as described in claim 6, characterized in that, The pressure of the atomizing medium in step (1) is 0.01~3MPa.
8. The method of using the multi-channel atomization ablation-electrolysis-chemical composite processing device as described in claim 7, characterized in that, In step (1), the solute in the electrolyte is one or more of Na2CO3, NaNO3 and NaCl.
9. The method of using the multi-channel atomization ablation-electrolysis-chemical composite processing device as described in claim 8, characterized in that, The concentration of the electrolyte in step (1) is 0.5~2.5wt%.
10. The method of using the multi-channel atomization ablation-electrolysis-chemical composite processing device as described in claim 9, characterized in that, The material of the workpiece in step (2) is a conductive material.