阵列微缝结构多线微细电解线切割加工技术基础研究

It is a great challenge to fabricate micro slit array in hard-to-machine metallic materials, which is a typical structure in high-tech products. Micro wire electrochemical machining is singularly appropriate to fabricate this kind of structure. It is necessary to improve its productivity to satisfy the machining requirement. In micro wire electrochemical machining, the productivity will be significantly improved by using multi-wire electrodes and the process is easy to control as the wire feed rate is constant. Therefore, multi-wire micro electrochemical machining is introduced to fabricate several micro slits one time by using multi wires as the cathode to machine the workpiece simultaneously. In the proposed technology, axial electrolyte flushing is adopted to remove the electrolysis products and renew the electrolyte in the machining gap, and auxiliary anode, which moves with the machining area, is used to eliminate the stray current. The relationship between productivity and machining area when ultra short pulses are used, the electrolyte flow status along the wire, and the effect of auxiliary anode on the process will be investigated. Key technologies, such as multi- wire in-situ fabrication, flux uniformity in multi nozzles, process status detection and control will be broken through. Micro slit array in hard-to-machine metallic materials with high quality will be produced efficiently by the proposed technology.

难加工金属材料阵列微缝是高新科技产品中经常涉及到的结构类型，其制造难度极大。微细电解线切割加工技术特别适合制造这类结构，但要满足制造需求，必须大幅提高其加工效率。本项目根据微细电解线切割的加工效率随加工的线电极数量大幅提高以及其控制简单易于实现多线同时加工的特性，提出多线微细电解线切割加工技术，利用规则排列的多根线电极对工件同时进行加工，一次完成多条微缝的加工。在提出的技术中，采用同轴冲液来排除加工间隙内的产物、补充新鲜电解液，同时提出与加工位置随动的辅助阳极来抑制杂散腐蚀。本项目将重点解决超短脉冲电流条件下加工效率与加工面积的内在联系、同轴冲液沿线电极电解液流动状态表征、随动式辅助阳极对加工过程的作用机制等基础科学问题，突破微细群线电极在线制备、多喷嘴电解液流量均匀化、加工状态的特征提取与控制等关键技术，解决难加工金属材料阵列微缝结构的高效、精密制造难题。

针对高新技术产品研制对阵列微缝结构的制造需求，本项目深入开展微细电解线切割加工技术研究，为提高其加工效率，提出了多线微细电解线切割加工技术，利用规则排列的多根线电极对工件同时进行加工，一次完成多条微缝的加工。对多线微细电解线切割加工的基础理论、试验系统、关键技术、工艺参数等进行了研究，揭示了超短脉冲电流条件下加工效率与加工面积的内在联系，建立了表征沿线电极电解液流动状态的数学模型，掌握了同轴冲液条件下微细电解线切割加工的流场特性，揭示了随动式辅助阳极对加工过程的作用机制，突破了微细群线电极在线制备、多喷嘴电解液流量均匀化、多线微细电解线切割加工状态特征提取与控制等关键技术。建立完善了多线电解线切割试验平台，开展了纳秒脉冲多线微细电解线切割加工试验、轴向冲液多线电解线切割加工试验、往复走丝多线电解线切割加工试验，掌握了线电极数量、进给速率、电解液性质、工件厚度、电参数等对加工的影响规律，实现了阵列微缝、微轴、微悬臂等典型微细阵列结构多线电解切割加工，最快稳定加工总速度达到75μm/s。通过本项目研究，实现了难加工金属材料阵列微缝结构的高效、精密制造。. 已发表/录用学术论文22篇，其中SCI源期刊18篇；申请国家发明专利6项，其中已授权5项；已毕业博士研究生2名，在读博士研究生1名，已毕业硕士研究生4名，在读硕士研究生2名。