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Fabrication of Taper Free Micro-Holes Utilizing a Combined Rotating Helical Electrode and Short Voltage Pulse by ECM

机译：利用ECM组合旋转螺旋电极和短电压脉冲制造无锥度微孔

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Fabrication of the injection nozzle micro-hole on the aero engine is a difficult problem in today’s manufacturing industry. In addition to the size requirements, the nozzle micro-hole also requires no burr, no taper and no heat-affected zone. To solve the above problem, an ultra-short voltage pulse and a high-speed rotating helical electrode were used in electrochemical drilling (ECD) process. Firstly, a theoretical model of ECD with ultra-short voltage pulse was established to investigate the effects of many predominant parameters on machining accuracy, and the effect of rotating helical electrode on the gap flow field was analyzed. Secondly, sets of experiments were carried out to investigate the effects of many key parameters on machining accuracy and efficiency. Finally, the optimized parameters were applied to machine micro holes on 500 μm thickness of GH4169 plate, and micro-holes with the diameter of 186 μm with no taper were machined at the feed rate of 1.2 μm/s. It is proved that the proposed ECD process for fabricating micro-holes with no taper has a huge potential and broad application prospects.
机译：在当今的制造业中，在航空发动机上制造喷嘴微孔是一个难题。除了尺寸要求外，喷嘴微孔还不需要毛刺，没有锥度和没有热影响区。为了解决上述问题，在电化学钻孔（ECD）工艺中使用了超短电压脉冲和高速旋转螺旋电极。首先，建立了具有超短电压脉冲的ECD的理论模型，以研究许多主要参数对加工精度的影响，并分析了螺旋电极旋转对间隙流场的影响。其次，进行了一系列实验以研究许多关键参数对加工精度和效率的影响。最后，将优化的参数应用于在GH4169板厚度为500μm的微孔上进行加工，并以1.2μm/ s的进给速度对直径为186μm无锥度的微孔进行加工。实践证明，提出的无锥度微孔加工的ECD工艺具有巨大的潜力和广阔的应用前景。

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