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电火花-电解复合穿孔(ECDD)加工方法有望实现难加工材料涡轮叶片气膜冷却孔无重铸层高效加工,为了进一步提升小孔孔壁的加工质量,提出了在工件底部填充冰层的电火花-电解复合穿孔加工新方法。分析了冰层辅助对复合加工过程中两极之间电流电压的波形、复合穿孔的加工效率、小孔的出入口孔径、孔壁重铸层去除等的影响,进行了冰层辅助与无冰层辅助电火花-电解复合穿孔对比试验。试验表明:冰层辅助加工可以在小孔穿透之后形成充分的反向冲液,有效地解决小孔穿透之后的漏液问题。在增加底部停顿时间的基础上,即小孔穿透后管电极到达预设深度继续停留一段时间,延长管电极对孔壁的电解作用时间,可以显著提高重铸层的去除效果,有望实现小孔整个孔壁重铸层的完全去除。
In order to further improve the processing quality of the small hole wall, the ECDD machining method is expected to realize the high efficiency machining of the hard film without the recast layer of the turbine cooling film on the turbine blade. A New Method of Spark - Electrolytic Composite Perforating. The effects of ice layer assist on the waveform of current and voltage between two poles, the processing efficiency of composite perforation, the entrance and exit aperture of small holes and the recast of pore wall were analyzed. The effects of ice layer aiding and ice-free layer aiding EDM - Electrolytic Composite Perforation Comparative Test. The experiment shows that the auxiliary processing of ice can form sufficient reverse flushing after penetrating the small hole and effectively solve the leakage problem after the small hole penetrating. On the basis of increasing the bottom pause time, after the small hole penetrates, the pipe electrode reaches a preset depth for a period of time to prolong the electrolysis time of the pipe electrode to the hole wall, which can remarkably improve the removal effect of the recast layer and is expected to achieve small Complete removal of the entire hole wall recast layer.