Study on influencing law of processing parameters in multi-aperture hole-making process with electro-hydraulic jet

电液束多孔径制孔工艺参数影响规律研究

¹ School of Mechanical Engineering, Northwestern Polytechnical University, Xi'an 710072, China
² Shaanxi Daobo Advanced Materials Science and Technology Co., Ltd., Xi'an 712000, China

Received: 19 February 2025

Abstract

Electro-hydraulic drilling has the advantages of high surface quality and no recast layer or microcracks. In the drilling, the optimization of the processing parameters has a significant influence on the hole diameter and quality. In this paper, the dynamic processing process of electro-hydraulic drilling is simulated and analyzed by using COMSOL software. The influences of the key processing parameters such as voltage, electrolyte conductivity and feed rate on the size of micro-holes are analyzed. Through the design of a set of drilling experiments, the high-precision straight holes with the diameters ranging from 0.5 mm to 1.0 mm were successfully drilled. The experimental results show that the hole diameter is positively correlated with the voltage and electrolyte conductivity, and negatively correlated with the feed rate. By optimizing the processing parameters, the high-quality micro-holes with a surface roughness of 1.28 μm were obtained. When the ratio of the target hole diameter to the outer diameter of the capillary exceeds 1.8 times, it will significantly affect the geometric accuracy (roundness and taper) of the hole. By increasing the diameter of the capillary, the roundness of the target hole is greatly improved.

摘要

电液束制孔具有表面质量高且无重铸层和微裂纹的优势, 实际加工中关键工艺参数对加工孔径和质量影响显著。利用COMSOL软件对电液束制孔的动态成形过程进行仿真, 分析加工电压、电解液电导率和进给速度等关键工艺参数对微小孔尺寸的影响; 通过设计系列化制孔实验, 成功实现了0.5~1.0 mm高精度直孔的加工。实验结果表明: 孔径尺寸与加工电压和电解液电导率呈正相关, 与进给速度呈负相关, 通过优化工艺参数, 最终获得了表面粗糙度达1.28 μm的高质量微小孔; 当加工目标孔径与毛细管外径比值超过1.8倍时, 将显著影响孔的几何精度(圆度和锥度), 通过增大毛细管直径, 目标孔的圆度得到明显提升。