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CN114505551A - Method for realizing integrated processing of special-shaped deep small holes with thermal barrier coatings by limiting liquid light transmission through dry ice - Google Patents

Method for realizing integrated processing of special-shaped deep small holes with thermal barrier coatings by limiting liquid light transmission through dry ice Download PDF

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CN114505551A
CN114505551A CN202210106542.1A CN202210106542A CN114505551A CN 114505551 A CN114505551 A CN 114505551A CN 202210106542 A CN202210106542 A CN 202210106542A CN 114505551 A CN114505551 A CN 114505551A
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dry ice
thermal barrier
deep
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CN114505551B (en
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刘洋
张朝阳
鲁金忠
薛伟
朱浩
徐坤
曹宇
张天帅
吴明颐
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Jiangsu University
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23HWORKING OF METAL BY THE ACTION OF A HIGH CONCENTRATION OF ELECTRIC CURRENT ON A WORKPIECE USING AN ELECTRODE WHICH TAKES THE PLACE OF A TOOL; SUCH WORKING COMBINED WITH OTHER FORMS OF WORKING OF METAL
    • B23H5/00Combined machining
    • B23H5/06Electrochemical machining combined with mechanical working, e.g. grinding or honing
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23HWORKING OF METAL BY THE ACTION OF A HIGH CONCENTRATION OF ELECTRIC CURRENT ON A WORKPIECE USING AN ELECTRODE WHICH TAKES THE PLACE OF A TOOL; SUCH WORKING COMBINED WITH OTHER FORMS OF WORKING OF METAL
    • B23H11/00Auxiliary apparatus or details, not otherwise provided for
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00Working by laser beam, e.g. welding, cutting or boring
    • B23K26/08Devices involving relative movement between laser beam and workpiece
    • B23K26/082Scanning systems, i.e. devices involving movement of the laser beam relative to the laser head
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00Working by laser beam, e.g. welding, cutting or boring
    • B23K26/14Working by laser beam, e.g. welding, cutting or boring using a fluid stream, e.g. a jet of gas, in conjunction with the laser beam; Nozzles therefor
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00Working by laser beam, e.g. welding, cutting or boring
    • B23K26/36Removing material
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00Working by laser beam, e.g. welding, cutting or boring
    • B23K26/70Auxiliary operations or equipment
    • B23K26/702Auxiliary equipment
    • B23K26/703Cooling arrangements
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02TCLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T50/00Aeronautics or air transport
    • Y02T50/60Efficient propulsion technologies, e.g. for aircraft

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  • Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • Optics & Photonics (AREA)
  • Mechanical Engineering (AREA)
  • Plasma & Fusion (AREA)
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  • Chemical Kinetics & Catalysis (AREA)
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  • Electrical Discharge Machining, Electrochemical Machining, And Combined Machining (AREA)

Abstract

The invention discloses a method for realizing integrated processing of a special-shaped deep small hole with a thermal barrier coating by restricting liquid light transmission by dry ice, which relates to the field of composite processing in special processing technology and comprises a special-shaped hole processing stage and a deep small hole processing stage; wherein, the laser beam is totally reflected by the inner tube of the hollow tube electrode to obtain a plurality of laser beams, and the electrolyte flows through the hollow tube electrode; the hollow tube electrode is connected with the negative pole of the pulse power supply, and the metal matrix is connected with the positive pole of the pulse power supply; processing a deep small hole on the basis of processing the special-shaped hole; and (3) a special-shaped hole machining stage: removing materials mainly by laser processing and secondarily by water jet; and (3) a deep small hole processing stage: laser, electrolysis and water jet work together to remove material. The method obviously improves the resolution of the laser milling special-shaped hole and cools the processing surface to avoid material layering by compressing the jet flow electrolyte water column diameter through the dry ice fluid, and realizes the integrated processing of the special-shaped hole and the deep small hole at the same station by adopting a processing tool.

Description

干冰约束液体传光实现带热障涂层异形深小孔一体化加工 方法Dry ice-constrained liquid light transmission to realize integrated processing of special-shaped deep and small holes with thermal barrier coating

技术领域technical field

本发明涉及特种加工技术中复合加工领域,尤其涉及到一种干冰约束液体传光实现带热障涂层异形深小孔一体化加工方法。The invention relates to the field of composite processing in special processing technology, in particular to a method for integrated processing of special-shaped deep and small holes with thermal barrier coatings by constraining liquid light transmission by dry ice.

背景技术Background technique

研究表明涡轮前燃气进口温度每提高约50℃,发动机效率就可提高10%。为了获得高效率和高推重比,涡轮前燃气进口温度不断被提高,例如美国F119发动机涡轮前燃气进口温度达到2000K,温度高于绝大多数材料的熔点[1]。目前,解决高温问题,主要从三个方面入手。第一,叶片本体采用耐高温的高温合金材料;第二,在叶片表面开设海量的气膜冷却孔以促进叶片表面冷却;第三,在叶片表面制备热障涂层以隔绝热量。发动机叶片气膜冷却孔排布密集、深径比高、空间角度复杂且孔口为异形孔 (簸箕孔)结构。高性能发动机采用的涡轮叶片对气膜冷却孔要求孔壁无重铸层、无微裂纹、无热影响区并且孔口光滑无毛刺。Studies have shown that for every 50°C increase in the gas inlet temperature before the turbine, the engine efficiency can be increased by 10%. In order to obtain high efficiency and high thrust-to-weight ratio, the gas inlet temperature before the turbine has been continuously increased. For example, the gas inlet temperature before the turbine of the American F119 engine reaches 2000K, which is higher than the melting point of most materials [1]. At present, solving the problem of high temperature mainly starts from three aspects. First, the blade body is made of high-temperature-resistant superalloy material; second, a large number of air film cooling holes are opened on the blade surface to promote cooling of the blade surface; third, a thermal barrier coating is prepared on the blade surface to isolate heat. The air film cooling holes of the engine blades are densely arranged, have a high aspect ratio, complex space angles, and the orifice is a special-shaped hole (dustpan hole) structure. Turbine blades used in high-performance engines require film cooling holes without recast layers, micro-cracks, heat-affected zones, and smooth orifices without burrs.

在国内,叶片气膜孔的加工流程是先在没有热障涂层的叶片表面加工深小孔,然后在叶片表面制备热障涂层,热障涂层经常会堵塞或缩小深小孔直径。In China, the processing flow of air film holes in blades is to first machine deep small holes on the surface of the blade without thermal barrier coating, and then prepare thermal barrier coating on the surface of the blade. Thermal barrier coating often blocks or reduces the diameter of deep small holes.

在国外,叶片气膜孔的加工流程通常是先在叶片表面制备热障涂层,然后再利用激光等工艺进行带涂层叶片的深小孔加工,这样可以有效保证深小孔的加工精度和质量。但这种方法也有缺陷,对于带热障涂层叶片,采用激光加工可以去除热障涂层,但加工金属深小孔时会产生重铸层及较大孔锥度;采用电解加工可以去除重铸层并实现无锥度加工,但无法去除加工区的热障涂层。In foreign countries, the machining process of the air film hole of the blade is usually to prepare the thermal barrier coating on the surface of the blade, and then use the laser and other processes to process the deep small hole of the coated blade, which can effectively ensure the machining accuracy of the deep small hole and quality. However, this method also has defects. For blades with thermal barrier coating, the thermal barrier coating can be removed by laser processing, but the recast layer and larger hole taper will be generated when processing deep and small metal holes; electrolytic machining can remove the recast layer. layer and achieve taper-free machining, but cannot remove the thermal barrier coating in the machined area.

总而言之,无法通过一种工艺实现带热障涂层深小孔的一体化加工。一些学者提出多步骤组合加工方式,先通过激光加工去除热障涂层,再利用电解加工深小孔。但这种组合加工方式要求机床主轴具有极高移动精度和定位精度,对激光加工后的异形孔位置进行精确定位后才能进行深小孔的电解加工,过程较为复杂。此外,激光扫描加工带热障涂层异形孔时即使利用水流冷却辅助也容易导致热障涂层与金属基体分层。All in all, the integrated machining of deep and small holes with thermal barrier coating cannot be achieved by one process. Some scholars have proposed a multi-step combined processing method, first removing the thermal barrier coating by laser processing, and then using electrolytic processing to deep small holes. However, this combined processing method requires the machine tool spindle to have extremely high moving accuracy and positioning accuracy, and the electrolytic machining of deep and small holes can only be performed after precise positioning of the laser-processed special-shaped holes, which is a complicated process. In addition, laser scanning processing of special-shaped holes with thermal barrier coating can easily lead to delamination of thermal barrier coating and metal substrate even with the aid of water flow cooling.

如何在实现带热障涂层异形深小孔高效高质量一体化加工,是实现高性能发动机叶片高效制造亟待解决的关键问题。How to realize high-efficiency and high-quality integrated processing of special-shaped deep and small holes with thermal barrier coating is a key problem to be solved to achieve high-efficiency manufacturing of high-performance engine blades.

发明内容SUMMARY OF THE INVENTION

针对现有技术中存在不足,本发明提供了一种干冰约束液体传光实现带热障涂层异形深小孔一体化加工方法,本发明通过干冰流体压缩射流电解液水柱直径,可以显著提高激光铣削加工异形孔的分辨率,在深小孔加工时,通过激光、电解和水射流共同作用去除材料可以实现深小孔的高效高质量加工。Aiming at the deficiencies in the prior art, the present invention provides an integrated processing method of dry ice constraining liquid light transmission to realize special-shaped deep and small holes with thermal barrier coating. The present invention compresses the diameter of the jet electrolyte water column by dry ice fluid, which can significantly improve the laser The resolution of milling special-shaped holes, when machining deep and small holes, removes materials through the combined action of laser, electrolysis and water jet, which can achieve efficient and high-quality machining of deep and small holes.

本发明是通过以下技术手段实现上述技术目的的。The present invention achieves the above technical purpose through the following technical means.

干冰约束液体传光实现带热障涂层异形深小孔一体化加工方法,包括异形孔加工阶段和深小孔加工阶段;其中,激光束经中空管电极内管全反射得到多个激光束,电解液流经中空管电极;中空管电极接脉冲电源负极,金属基体接脉冲电源正极;在异形孔的加工基础上加工深小孔;Dry ice-constrained liquid light transmission to realize the integrated processing method of special-shaped deep small holes with thermal barrier coating, including special-shaped hole processing stage and deep small hole processing stage; wherein, the laser beam is totally reflected by the inner tube of the hollow tube electrode to obtain multiple laser beams , the electrolyte flows through the hollow tube electrode; the hollow tube electrode is connected to the negative electrode of the pulse power supply, and the metal substrate is connected to the positive electrode of the pulse power supply; deep small holes are processed on the basis of the processing of special-shaped holes;

异形孔加工阶段:通过干冰流体压缩射流电解液水柱的直径,提高激光铣削加工异形孔的分辨率,同时利用干冰流体的低温快速冷却加工表面进而避免热障涂层与金属基体之间发生分层,异形孔加工阶段以激光加工为主、水射流为辅去除材料;Special-shaped hole processing stage: The diameter of the jet electrolyte water column is compressed by the dry ice fluid to improve the resolution of laser milling to process the special-shaped hole. At the same time, the low temperature of the dry ice fluid is used to rapidly cool the machined surface to avoid delamination between the thermal barrier coating and the metal substrate. , In the processing stage of special-shaped holes, laser processing is mainly used, and water jet is auxiliary to remove materials;

深小孔加工阶段:干冰流体不再压缩电解液水柱而是约束深小孔出口处流出的浑浊电解液,激光与电解耦合加工,激光去除阻碍电解加工的氧化层,电解溶解激光加工产生的重铸层并降低加工表面粗糙度,高速流动的电解液带走加工产物,深小孔加工阶段激光、电解和水射流共同作用去除材料以实现深小孔的加工。Deep hole processing stage: dry ice fluid no longer compresses the electrolyte water column but constrains the turbid electrolyte flowing out of the deep hole outlet, laser and electrolytic coupling processing, laser removal of the oxide layer that hinders electrolytic processing, electrolytic dissolution of the heavy metal produced by laser processing. Cast layer and reduce the roughness of the machined surface, the high-speed flowing electrolyte takes away the processed products, and the laser, electrolysis and water jet work together to remove the material in the deep small hole processing stage to realize the deep small hole processing.

上述方案中,中空管电极固定不动,夹具包裹中空管电极外侧壁,并且夹具相对中空管电极位置在竖直方向上可调,夹具上开设有流道,干冰流体通过流道沿中空管电极外侧壁向下流动,通过调节夹具相对中空管电极的位置可以实现干冰流体压缩射流电解液水柱直径或者约束深小孔出口处流出的浑浊电解液。In the above scheme, the hollow tube electrode is fixed, the clamp wraps the outer side wall of the hollow tube electrode, and the position of the clamp relative to the hollow tube electrode is adjustable in the vertical direction, the clamp is provided with a flow channel, and the dry ice fluid passes through the flow channel along the The outer wall of the hollow tube electrode flows downward, and by adjusting the position of the clamp relative to the hollow tube electrode, the diameter of the water column of the jet electrolyte can be compressed by the dry ice fluid or the turbid electrolyte flowing out of the outlet of the deep orifice can be restricted.

上述方案中,中空管电极下端被夹具包裹时,干冰流体压缩射流电解液水柱直径;中空管电极下端凸出于夹具时,干冰流体约束深小孔出口处流出的浑浊电解液。In the above scheme, when the lower end of the hollow tube electrode is wrapped by the clamp, the dry ice fluid compresses the diameter of the water column of the jet electrolyte; when the lower end of the hollow tube electrode protrudes from the clamp, the dry ice fluid constrains the turbid electrolyte flowing out of the outlet of the deep orifice.

上述方案中,异形孔加工阶段,电解液水柱从中空管电极流出到加工表面之间的形状为倒圆锥形。In the above solution, in the processing stage of the special-shaped hole, the shape of the electrolyte water column flowing out from the hollow tube electrode to the processing surface is an inverted conical shape.

上述方案中,流道截面呈Y字形结构。In the above scheme, the cross section of the flow channel is in a Y-shaped structure.

上述方案中,所述中空管电极包括内层的氟聚物管和外层的金属管,其中,所述金属管与氟聚物管紧密贴合且高度同轴,金属管外表面制备有绝缘涂层。In the above solution, the hollow tube electrode comprises an inner fluoropolymer tube and an outer metal tube, wherein the metal tube is closely attached to the fluoropolymer tube and is highly coaxial, and the outer surface of the metal tube is prepared with insulating coating.

上述方案中,所述夹具为金属材料,夹具上连接有温控装置,通过温控装置对夹具加热或者冷却,从而对流道内干冰流体加热或者冷却,最终控制干冰流体的形态,其中,干冰流体的形态为固态颗粒形态、固气混合态或者纯气态。In the above scheme, the clamp is made of metal material, and the clamp is connected with a temperature control device, and the clamp is heated or cooled by the temperature control device, thereby heating or cooling the dry ice fluid in the flow channel, and finally controlling the shape of the dry ice fluid, wherein, the dry ice fluid is formed. The form is solid particle form, solid-gas mixture or pure gas.

上述方案中,异形孔开设在热障涂层上;异形孔的形状结构可根据扫描加工轨迹得到。In the above solution, the special-shaped hole is opened on the thermal barrier coating; the shape and structure of the special-shaped hole can be obtained according to the scanning processing track.

上述方案中,在异形孔加工阶段和深小孔加工阶段,带热障涂层的金属基体在数控系统的控制下在三维空间内移动,中空管电极保持静止,夹具上下移动。In the above scheme, in the special-shaped hole processing stage and the deep small hole processing stage, the metal substrate with thermal barrier coating moves in the three-dimensional space under the control of the numerical control system, the hollow tube electrode remains stationary, and the fixture moves up and down.

上述方案中,通过控制干冰流体的流向、流速参数可以控制电解液水柱的直径大小,从而实现不同分辨率和不同加工效率的异形孔加工,在需要高分辨率的工况下将电解液水柱直径压缩到很小的尺寸以实现精密微结构加工,在不需要高分辨率的工况下相对增大电解液水柱的直径以实现高效大面积加工。In the above scheme, the diameter of the electrolyte water column can be controlled by controlling the flow direction and flow rate parameters of the dry ice fluid, so as to realize the processing of special-shaped holes with different resolutions and different processing efficiencies. It can be compressed to a small size to achieve precise microstructure processing, and the diameter of the electrolyte water column can be relatively increased to achieve high-efficiency large-area processing under conditions that do not require high resolution.

本发明具有如下优点:The present invention has the following advantages:

1.本发明方法中干冰流体压缩射流电解液水柱直径,以提高激光铣削加工异形孔的分辨率,同时干冰流体的低温可快速冷却加工表面进而避免热障涂层与金属层之间分层。1. In the method of the present invention, the dry ice fluid compresses the diameter of the water column of the jet electrolyte to improve the resolution of the laser milling special-shaped holes, and the low temperature of the dry ice fluid can rapidly cool the machined surface to avoid delamination between the thermal barrier coating and the metal layer.

2.热障涂层上开设的异形孔和内部深小孔的加工在同一工位,加工中途不需要更换工具电极,不需要重复定位,减少加工工艺步骤,提高加工效率和质量。2. The special-shaped holes opened on the thermal barrier coating and the inner deep small holes are processed in the same station. There is no need to replace the tool electrode during the processing, and there is no need to repeat the positioning, which reduces the processing steps and improves the processing efficiency and quality.

3.干冰流体可以提高电解液射流流体的稳定性,避免射流加工时流体发散失稳,提高激光光束在电解液水柱中传光的稳定性。3. Dry ice fluid can improve the stability of electrolyte jet fluid, avoid fluid divergence and instability during jet processing, and improve the stability of laser beam transmission in the electrolyte water column.

附图说明Description of drawings

图1为本发明实施例涉及到的干冰流体约束电解液实现高分辨率激光铣削带热障涂层异形孔示意图;1 is a schematic diagram of the implementation of high-resolution laser milling of special-shaped holes with thermal barrier coatings by the dry ice fluid confinement electrolyte involved in the embodiment of the present invention;

图2为本发明表面异形孔激光铣削加工工艺流程示意图Fig. 2 is a schematic diagram of the process flow of laser milling processing of surface special-shaped holes according to the present invention

图3为本发明内部深小孔激光电化学耦合加工工艺流程示意图;3 is a schematic diagram of the process flow of the laser electrochemical coupling processing of the internal deep small holes of the present invention;

图4为本发明全反射激光与射流电解耦合加工深小孔示意图。FIG. 4 is a schematic diagram of the electrolytic coupling of total reflection laser and jet to process deep small holes according to the present invention.

附图标记:Reference number:

1-聚焦透镜;2-中空管电极;3-电解液水柱;4-激光束;5-深小孔;6-金属基体;7-热障涂层;8-异形孔;9-倒圆锥形态的电解液;10夹具;11-干冰流体;12-电解液;13-流出的浑浊电解液;14-绝缘涂层;15-金属管;16-氟聚物管。1- Focusing lens; 2- Hollow tube electrode; 3- Electrolyte water column; 4- Laser beam; 5- Deep hole; 6- Metal substrate; 7- Thermal barrier coating; 8- Special-shaped hole; 9- Inverted cone 10-clamp; 11-dry ice fluid; 12-electrolyte; 13-outflowing cloudy electrolyte; 14-insulating coating; 15-metal tube; 16-fluoropolymer tube.

具体实施方式Detailed ways

下面详细描述本发明的实施例,所述实施例的示例在附图中示出,其中自始至终相同或类似的标号表示相同或类似的元件或具有相同或类似功能的元件。下面通过参考附图描述的实施例是示例性的,旨在用于解释本发明,而不能理解为对本发明的限制。The following describes in detail the embodiments of the present invention, examples of which are illustrated in the accompanying drawings, wherein the same or similar reference numerals refer to the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary, and are intended to explain the present invention and should not be construed as limiting the present invention.

在本发明的描述中,需要理解的是,术语“中心”、“纵向”、“横向”、“长度”、“宽度”、“厚度”、“上”、“下”、“轴向”、“径向”、“竖直”、“水平”、“内”、“外”等指示的方位或位置关系为基于附图所示的方位或位置关系,仅是为了便于描述本发明和简化描述,而不是指示或暗示所指的装置或元件必须具有特定的方位、以特定的方位构造和操作,因此不能理解为对本发明的限制。此外,术语“第一”、“第二”仅用于描述目的,而不能理解为指示或暗示相对重要性或者隐含指明所指示的技术特征的数量。由此,限定有“第一”、“第二”的特征可以明示或者隐含地包括一个或者更多个该特征。在本发明的描述中,“多个”的含义是两个或两个以上,除非另有明确具体的限定。In the description of the present invention, it should be understood that the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "upper", "lower", "axial", The orientation or positional relationship indicated by "radial", "vertical", "horizontal", "inner", "outer", etc. is based on the orientation or positional relationship shown in the drawings, and is only for the convenience of describing the present invention and simplifying the description , rather than indicating or implying that the indicated device or element must have a particular orientation, be constructed and operate in a particular orientation, and therefore should not be construed as limiting the invention. In addition, the terms "first" and "second" are only used for descriptive purposes, and should not be construed as indicating or implying relative importance or implying the number of indicated technical features. Thus, a feature defined as "first", "second" may expressly or implicitly include one or more of that feature. In the description of the present invention, "plurality" means two or more, unless otherwise expressly and specifically defined.

在本发明中,除非另有明确的规定和限定,术语“安装”、“相连”、“连接”、“固定”等术语应做广义理解,例如,可以是固定连接,也可以是可拆卸连接,或一体地连接;可以是机械连接,也可以是电连接;可以是直接相连,也可以通过中间媒介间接相连,可以是两个元件内部的连通。对于本领域的普通技术人员而言,可以根据具体情况理解上述术语在本发明中的具体含义。In the present invention, unless otherwise expressly specified and limited, the terms "installed", "connected", "connected", "fixed" and other terms should be understood in a broad sense, for example, it may be a fixed connection or a detachable connection , or integrally connected; it can be a mechanical connection or an electrical connection; it can be a direct connection, or an indirect connection through an intermediate medium, or the internal communication between the two components. For those of ordinary skill in the art, the specific meanings of the above terms in the present invention can be understood according to specific situations.

干冰约束液体传光实现带热障涂层异形深小孔一体化加工方法,在表层带热障涂层2的金属基体6上加工异形孔8时,通过干冰流体11压缩射流电解液水柱3直径,提高激光铣削加工异形孔8的分辨率,同时利用干冰流体11的低温快速冷却工件加工表面进而避免热障涂层7与金属基体6之间发生分层,该阶段以激光加工为主、水射流为辅去除材料;在金属基体6上加工内部深小孔5时,干冰流体11不再压缩电解液水柱3而是约束深小孔出口处流出的浑浊电解液13,激光与电解耦合加工,激光去除阻碍电解加工的氧化层,电解溶解激光加工产生的重铸层并降低加工表面粗糙度,高速流动的电解液带走加工产物,该阶段激光、电解和水射流共同作用去除材料以实现深小孔5的高效高质量加工。本发明方法通过干冰流体压缩射流电解液水柱直径,显著的提高了激光铣削加工异形孔的分辨率。Dry ice constrains liquid light transmission to realize the integrated processing method of special-shaped deep and small holes with thermal barrier coating. When processing special-shaped holes 8 on metal substrate 6 with thermal barrier coating 2 on the surface, the diameter of jet electrolyte water column 3 is compressed by dry ice fluid 11 , to improve the resolution of laser milling processing special-shaped holes 8, and at the same time use the low temperature of the dry ice fluid 11 to rapidly cool the workpiece surface to avoid delamination between the thermal barrier coating 7 and the metal substrate 6. This stage is mainly laser processing, water The jet is used to remove the material; when the inner deep hole 5 is processed on the metal substrate 6, the dry ice fluid 11 no longer compresses the electrolyte water column 3 but constrains the turbid electrolyte 13 flowing out from the outlet of the deep hole, and the laser and electrolysis are coupled to process, The laser removes the oxide layer that hinders the electrolytic machining, the electrolytic dissolves the recast layer produced by the laser machining and reduces the machining surface roughness, and the high-speed flowing electrolyte takes away the processed products. At this stage, the laser, electrolysis and water jet work together to remove the material to achieve deep depth. Efficient and high-quality machining of small holes 5. In the method of the invention, the diameter of the water column of the jet electrolyte is compressed by the dry ice fluid, and the resolution of the laser milling processing special-shaped holes is significantly improved.

工件表面带热障涂层7的金属基体6上加工异形孔8和内部深小孔5时,加工使用同一套工具,在同一工位,加工中途不需要更换工具,不需要重复定位,降低了对机床控制系统定位精度的要求,简化了加工工艺步骤,提高加工效率和质量。一体化加工在同一工位,采用统一工艺,不更换加工工具,相比于组合式多工位加工可以显著提高加工效率、降低多工位转移时定位误差。When machining the special-shaped hole 8 and the inner deep small hole 5 on the metal base 6 with the thermal barrier coating 7 on the surface of the workpiece, the same set of tools is used for machining, and in the same station, there is no need to replace the tool during the machining, and there is no need to repeat the positioning. The requirements for the positioning accuracy of the machine tool control system simplify the processing steps and improve the processing efficiency and quality. Integrated processing in the same station, using a unified process, without changing the processing tools, compared with the combined multi-station processing, it can significantly improve the processing efficiency and reduce the positioning error during multi-station transfer.

通过控制干冰流体11的流向、流速等参数可以控制电解液水柱3的直径大小,从而实现不同分辨率和不同加工效率的异形孔8加工,在需要高分辨率的工况下将电解液水柱3直径压缩到很小的尺寸以实现精密微结构加工,在不需要高分辨率的工况下增大电解液水柱3的直径以实现高效大面积加工。干冰流体的有效控制,可以提高本发明方法一体化加工方法的柔性,使其能满足更多加工需求,通过干冰流体对电解液水柱直径的约束控制来分别针对不同需求实现高精度加工或者高效率加工。By controlling the flow direction, flow rate and other parameters of the dry ice fluid 11, the diameter of the electrolyte water column 3 can be controlled, thereby realizing the processing of special-shaped holes 8 with different resolutions and different processing efficiencies. The diameter is compressed to a very small size to achieve precise microstructure processing, and the diameter of the electrolyte water column 3 is increased to achieve efficient large-area processing under the condition that high resolution is not required. The effective control of the dry ice fluid can improve the flexibility of the integrated processing method of the method of the present invention, so that it can meet more processing requirements. Through the constraint control of the diameter of the electrolyte water column by the dry ice fluid, high-precision processing or high-efficiency can be respectively realized according to different requirements. processing.

干冰流体11本身为微颗粒,在室温下升华气化过程大量吸收入热量进而快速降低电解液温度,并冲击到异形孔8加工周边区域,在低温电解液和低温干冰双重冷却下有效避免激光热量集聚造成热障涂层7和金属基体6之间发生分层,并且可以减弱激光热量对工件本体微观组织性能产生不良影响。本发明方法通过干冰流体和低温电解液双重冷却结合电解液的高速冲刷可以有效避免激光加工热量的集聚,进而避免激光热量导致热障涂层与金属基体的分层。The dry ice fluid 11 itself is a micro-particle, which absorbs a large amount of heat during the sublimation and gasification process at room temperature, thereby rapidly reducing the temperature of the electrolyte, and impacts the processing peripheral area of the special-shaped hole 8, effectively avoiding the laser heat under the dual cooling of the low-temperature electrolyte and low-temperature dry ice. The agglomeration causes delamination between the thermal barrier coating 7 and the metal substrate 6, and can reduce the adverse effects of laser heat on the microstructure properties of the workpiece body. The method of the invention can effectively avoid the accumulation of laser processing heat by double cooling of dry ice fluid and low-temperature electrolyte combined with high-speed scouring of the electrolyte, thereby avoiding the delamination of the thermal barrier coating and the metal substrate caused by the laser heat.

干冰流体11和电解液流体共同冲击加工区,可以对加工区造成一定的冲击力效应,快速带走加工产物与热量。电解加工产物通常为絮状物,具有一定粘附性,水流冲击力不足的情况下很难将电解加工产物快速带出加工区,本发明方法中提出的干冰流体和电解液流体双重冲刷方式有助于高效冲刷带走具有粘附性的电解加工产物。The dry ice fluid 11 and the electrolyte fluid impinge on the processing area together, which can cause a certain impact force to the processing area and quickly take away the processing products and heat. Electrolytically processed products are usually flocs with certain adhesion, and it is difficult to quickly bring the electrolytically processed products out of the processing area when the impact force of the water flow is insufficient. The double flushing method of dry ice fluid and electrolyte fluid proposed in the method of the present invention has Helps in efficient scouring to remove sticky ECM products.

干冰流体11在整个加工过程中都起作用,其不仅约束电解液的流动,在干冰流体11还可以将连续的电解液流体分割成不连续的液滴,进而避免了连续的电解液流动到非加工区对非加工区产生损伤。根据电化学反应原理,只要在阴极和阳极之间有连续的导电介质(电解液),在电解液覆盖的阳极表面就会产生电化学腐蚀。本发明方法中通过干冰流体冲击约束电解液周边区域可以切断连续的电解液对加工区周边的电化学腐蚀电路。The dry ice fluid 11 works throughout the process, not only constraining the flow of the electrolyte, but also dividing the continuous electrolyte fluid into discrete droplets in the dry ice fluid 11, thereby avoiding the continuous flow of electrolyte to non-continuous droplets. The processing area causes damage to the non-processing area. According to the principle of electrochemical reaction, as long as there is a continuous conductive medium (electrolyte) between the cathode and the anode, electrochemical corrosion will occur on the surface of the anode covered by the electrolyte. In the method of the present invention, the continuous electrolyte corrosion circuit of the surrounding area of the processing area can be cut off by the impact of the dry ice fluid on the surrounding area of the confinement electrolyte.

在内部深小孔5的加工当中,通过夹具10的移动来改变夹具10与中空管电极2之间的相对位置关系,干冰流体11的流向也发生变化,干冰流体11开始作用于深小孔5的孔口处,约束从孔口处流出的浑浊电解液13,避免流出的浑浊电解液13从内向外对热障涂层7产生冲击进而实现对热障涂层7的保护。电化学腐蚀很容易导致热障涂层开裂和失效,通过干冰流体约束孔口处流出的电解液的流动,可以有效减弱孔口处热障涂层遭受电化学腐蚀,进而避免其开裂和失效。During the processing of the inner deep hole 5, the relative positional relationship between the fixture 10 and the hollow tube electrode 2 is changed by the movement of the fixture 10, and the flow direction of the dry ice fluid 11 also changes, and the dry ice fluid 11 begins to act on the deep small hole. At the orifice of 5, the turbid electrolyte 13 flowing out from the orifice is restrained, so as to prevent the turbid electrolyte 13 flowing out from impacting the thermal barrier coating 7 from the inside to the outside, thereby realizing the protection of the thermal barrier coating 7. Electrochemical corrosion can easily lead to the cracking and failure of the thermal barrier coating. By restricting the flow of the electrolyte flowing out of the orifice by dry ice fluid, the electrochemical corrosion of the thermal barrier coating at the orifice can be effectively weakened, thereby avoiding its cracking and failure.

整个加工过程中,干冰流体11、电解液流体、激光光束4以及电解电路都是接通的,只需根据异形孔8形状结构设计扫描加工轨迹即可;中空管电极的金属管接通电解电源的负极,工件的金属基体接通电解电源的正极。During the whole processing process, the dry ice fluid 11, the electrolyte fluid, the laser beam 4 and the electrolysis circuit are all connected, and it is only necessary to scan the processing track according to the shape and structure design of the special-shaped hole 8; the metal tube of the hollow tube electrode is connected to the electrolysis The negative pole of the power supply, the metal substrate of the workpiece is connected to the positive pole of the electrolytic power supply.

整个加工过程中,中空管电极2的金属管15接通电解电源的负极,工件的金属基体6接通电解电源的正极。中空管电极2是由两层管组成,内层是氟聚物管16,激光束4以一定角度从流入的电解液12入射到氟聚物管16表面可以发生全反射,外层是金属管15,金属管15 是通过精密电铸制作而成,金属管15具有端部突出的特点,金属管15与内层的氟聚物管16 紧密贴合且高度同轴,金属管15外表面通过电泳绝缘工艺制备有绝缘涂层14。精密电铸制作的金属管15端部突出可以增强中空管电极2端部电场,进而提高加工效率,外表面电泳绝缘可以避免中空管电极外侧壁对深小孔的二次电解,避免产生锥形孔。During the whole process, the metal tube 15 of the hollow tube electrode 2 is connected to the negative electrode of the electrolytic power supply, and the metal base 6 of the workpiece is connected to the positive electrode of the electrolytic power supply. The hollow tube electrode 2 is composed of two layers of tubes, the inner layer is a fluoropolymer tube 16, the laser beam 4 can be totally reflected from the inflowing electrolyte 12 incident on the surface of the fluoropolymer tube 16 at a certain angle, and the outer layer is a metal tube. The tube 15 and the metal tube 15 are made by precision electroforming. The metal tube 15 has the characteristic of protruding ends. The metal tube 15 is closely attached to the inner fluoropolymer tube 16 and is highly coaxial. The outer surface of the metal tube 15 The insulating coating 14 is prepared by an electrophoretic insulating process. The protruding end of the metal tube 15 made by precision electroforming can enhance the electric field at the end of the hollow tube electrode 2, thereby improving the processing efficiency. Conical hole.

整个加工过程中工件在数控系统的控制下在三维空间内移动,中空管电极2保持静止,夹具10上下移动,夹具10可以独立上下移动以改变于中空管电极2的相对位置。During the whole machining process, the workpiece moves in three-dimensional space under the control of the numerical control system, the hollow tube electrode 2 remains stationary, the fixture 10 moves up and down, and the fixture 10 can move up and down independently to change the relative position of the hollow tube electrode 2 .

夹具10内部开设有干冰流体11的流道,流道截面为Y字形结构,具体的,流道整体为收缩式的结构,流道的一部分与中空管电极2贴合,其流道整体呈现斜向下的趋势,环形围绕着中空管电极2。The inside of the fixture 10 is provided with a flow channel for the dry ice fluid 11, and the cross section of the flow channel is a Y-shaped structure. Specifically, the entire flow channel is a retractable structure, and a part of the flow channel is fitted with the hollow tube electrode 2, and the flow channel as a whole presents The trend is inclined downward, and the ring surrounds the hollow tube electrode 2 .

夹具10本体为金属结构并连接温控装置,通过温控装置可以对夹具10本体金属进行加热或冷却,进而实现对流道内干冰流体11的加热和冷却,最终控制干冰流体11的形态,其中,干冰流体11为固态颗粒形态、固气混合态或纯气态。The body of the fixture 10 is a metal structure and is connected to a temperature control device. Through the temperature control device, the metal of the body of the fixture 10 can be heated or cooled, thereby realizing the heating and cooling of the dry ice fluid 11 in the flow channel, and finally controlling the shape of the dry ice fluid 11. The fluid 11 is in the form of solid particles, solid-gas mixture or pure gas.

结合附图1所示,加工开始之前,首先通过数控系统调整工件位置,将工件调整到距离加工工具较近的位置,接通电解液,待流入的新鲜电解液在中空管电极内流动稳定后打开干冰流体供给系统,通过调节干冰流体的流速、角度等参数以及夹具体的位置实现对电解液的有效约束,使得电解液从圆柱形态转变为圆锥形态。当电解液和干冰流体都处于稳定状态时,打开激光器,设置较低的激光功率,通过调节激光光路将激光光束引入到中空管电极内腔中,激光光束通过多次全反射到达加工区表面。当激光光路调整完毕后,设置工件移动轨迹以便于实现异形孔逐层扫描加工,将激光功率调整到合适的参数正式开始异形孔加工。As shown in Figure 1, before the processing starts, first adjust the workpiece position through the numerical control system, adjust the workpiece to a position closer to the processing tool, connect the electrolyte, and the fresh electrolyte to be flown flows stably in the hollow tube electrode. Then, the dry ice fluid supply system is turned on, and the electrolyte is effectively constrained by adjusting the flow rate, angle and other parameters of the dry ice fluid and the position of the clamp body, so that the electrolyte changes from a cylindrical shape to a conical shape. When both the electrolyte and dry ice fluid are in a stable state, turn on the laser, set a low laser power, and introduce the laser beam into the cavity of the hollow tube electrode by adjusting the laser light path. The laser beam reaches the surface of the processing area through multiple total reflections. . After the adjustment of the laser light path is completed, the workpiece movement track is set so as to realize the layer-by-layer scanning processing of the special-shaped hole, and the laser power is adjusted to the appropriate parameters to officially start the processing of the special-shaped hole.

结合附图2到图4所示,当工件表面异形孔加工完毕之后,如图2,工件开始旋转一定角度,转入深小孔加工,此时夹具体的上移,如图3。干冰流体的流道受到中空管电极的约束开始沿管电极的外侧壁面流动,当遇到深小孔孔口流出的浑浊电解液时将电解液连续流体转化为气液混合的雾状,从而切断浑浊电解液的连续导电液体回路,避免浑浊电解液对热障涂层以及加工区周边的非加工区产生杂散腐蚀,如图4。As shown in Figures 2 to 4, when the special-shaped hole on the workpiece surface is processed, as shown in Figure 2, the workpiece starts to rotate at a certain angle, and turns to deep small hole processing. At this time, the clamping body moves up, as shown in Figure 3. The flow channel of the dry ice fluid is constrained by the hollow tube electrode and begins to flow along the outer wall surface of the tube electrode. When encountering the turbid electrolyte flowing out of the deep orifice, the continuous fluid of the electrolyte is converted into a mist of gas-liquid mixing, thereby Cut off the continuous conductive liquid loop of the turbid electrolyte to avoid stray corrosion of the turbid electrolyte to the thermal barrier coating and the non-processing area around the processing area, as shown in Figure 4.

在本说明书的描述中,参考术语“一个实施例”、“一些实施例”、“示例”、“具体示例”、或“一些示例”等的描述意指结合该实施例或示例描述的具体特征、结构、材料或者特点包含于本发明的至少一个实施例或示例中。在本说明书中,对上述术语的示意性表述不一定指的是相同的实施例或示例。而且,描述的具体特征、结构、材料或者特点可以在任何的一个或多个实施例或示例中以合适的方式结合。In the description of this specification, description with reference to the terms "one embodiment," "some embodiments," "example," "specific example," or "some examples", etc., mean specific features described in connection with the embodiment or example , structure, material or feature is included in at least one embodiment or example of the present invention. In this specification, schematic representations of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the particular features, structures, materials or characteristics described may be combined in any suitable manner in any one or more embodiments or examples.

尽管上面已经示出和描述了本发明的实施例,可以理解的是,上述实施例是示例性的,不能理解为对本发明的限制,本领域的普通技术人员在不脱离本发明的原理和宗旨的情况下在本发明的范围内可以对上述实施例进行变化、修改、替换和变型。Although the embodiments of the present invention have been shown and described above, it should be understood that the above embodiments are exemplary and should not be construed as limiting the present invention, and those of ordinary skill in the art will not depart from the principles and spirit of the present invention Variations, modifications, substitutions, and alterations to the above-described embodiments are possible within the scope of the present invention without departing from the scope of the present invention.

Claims (10)

1. The method for realizing the integrated processing of the special-shaped deep small hole with the thermal barrier coating by restricting the liquid light transmission by the dry ice is characterized by comprising a special-shaped hole processing stage and a deep small hole processing stage; wherein, the laser beams (4) are totally reflected by the inner tube of the hollow tube electrode (2) to obtain a plurality of laser beams (4), and the electrolyte flows through the hollow tube electrode (2); the hollow tube electrode (2) is connected with the negative pole of the pulse power supply, and the metal matrix (6) is connected with the positive pole of the pulse power supply; processing a small deep hole (5) on the basis of processing the special-shaped hole (8);
and (3) a special-shaped hole machining stage: the diameter of a jet electrolyte water column (3) is compressed through a dry ice fluid (11), the resolution of a laser milling special-shaped hole (8) is improved, meanwhile, the low-temperature quick cooling processing surface of the dry ice fluid (11) is utilized to further avoid the layering between a thermal barrier coating (7) and a metal matrix (6), and materials are removed mainly by laser processing and assisted by water jet in the special-shaped hole processing stage;
and (3) a deep small hole processing stage: the dry ice fluid (11) does not compress the electrolyte water column (3) any more but restrains turbid electrolyte (13) flowing out of the outlet of the deep pore (5), laser and electrolysis coupling processing is carried out, an oxide layer which hinders electrolysis processing is removed by the laser, a recast layer generated by laser processing is dissolved by electrolysis and the processing surface roughness is reduced, a processed product is taken away by the electrolyte flowing at a high speed, and materials are removed under the combined action of the laser, electrolysis and water jet in the deep pore processing stage so as to realize the processing of the deep pore (5).
2. The method for integrally processing the special-shaped deep small hole with the thermal barrier coating by constraining the liquid to transmit light through the dry ice according to claim 1 is characterized in that a hollow tube electrode (2) is fixed, a clamp (10) wraps the outer side wall of the hollow tube electrode (2), the position of the clamp (10) relative to the hollow tube electrode (2) is adjustable in the vertical direction, a flow channel is formed in the clamp (10), the dry ice fluid (11) flows downwards along the outer side wall of the hollow tube electrode (2) through the flow channel, and the dry ice fluid (11) can compress the diameter of a jet electrolyte water column (3) or constrain turbid electrolyte (13) flowing out of an outlet of the deep small hole (5) by adjusting the position of the clamp (10) relative to the hollow tube electrode (2).
3. The method for integrally processing the special-shaped deep small hole with the thermal barrier coating by constraining the liquid to transmit light by the dry ice according to claim 2, wherein when the lower end of the hollow tube electrode (2) is wrapped by the clamp (10), the dry ice fluid (11) compresses the diameter of the jet flow electrolyte water column (3); when the lower end of the hollow tube electrode (2) protrudes out of the clamp (10), the dry ice fluid (11) restricts turbid electrolyte (13) flowing out of the outlet of the deep small hole (5).
4. A dry ice constrained liquid light transmission method for realizing irregular deep and small holes with thermal barrier coatings integrally machining according to any one of claims 2 or 3, characterized in that in the irregular hole machining stage, the shape of an electrolyte water column (3) flowing out from a hollow tube electrode (2) to the machined surface under the constraint of dry ice fluid (11) is an inverted cone.
5. The method for integrally processing the special-shaped deep small hole with the thermal barrier coating by restraining the liquid and transmitting the light according to the claim 2, wherein the cross section of the flow channel is of a Y-shaped structure.
6. The dry ice-constrained liquid light transmission method for realizing the integration of the special-shaped deep small hole with the thermal barrier coating according to the claim 1 is characterized in that the hollow tube electrode (2) comprises an inner fluoropolymer tube (16) and an outer metal tube (15), wherein the metal tube (15) is tightly attached to and highly coaxial with the fluoropolymer tube (16), and the outer surface of the metal tube (15) is provided with the insulating coating (14).
7. The dry ice constraint liquid light transmission implementation thermal barrier coating special-shaped deep small hole integrated processing method according to claim 2, characterized in that the clamp (10) is made of metal material, a temperature control device is connected to the clamp, the clamp (10) is heated or cooled through the temperature control device, so that the dry ice fluid (11) in the flow channel is heated or cooled, and finally the form of the dry ice fluid (11) is controlled, wherein the form of the dry ice fluid (11) is solid particle form, solid-gas mixed form or pure gas form.
8. The dry ice constraint liquid light transmission realization with thermal barrier coating dysmorphism deep hole integrated processing method of claim 1, characterized by that, the hole of dysmorphism (8) is offered on thermal barrier coating (7); the shape structure of the special-shaped hole (8) can be obtained according to a scanning processing track.
9. The method for integrally processing the special-shaped deep small hole with the thermal barrier coating by constraining the liquid and transmitting the light according to the dry ice in the claim 1 is characterized in that in a special-shaped hole processing stage and a deep small hole processing stage, a metal base body (6) with the thermal barrier coating (7) moves in a three-dimensional space under the control of a numerical control system, a hollow tube electrode (2) is kept static, and a clamp (10) moves up and down.
10. The method for integrally processing the special-shaped deep small hole with the thermal barrier coating by constraining the liquid to transmit light through the dry ice according to claim 1, wherein the diameter of the electrolyte water column (3) can be controlled by controlling the flow direction and the flow speed parameters of the dry ice fluid (11), so that the special-shaped holes (8) with different resolutions and different processing efficiencies are processed, the diameter of the electrolyte water column (3) is compressed to a small size under the working condition that high resolution is required to realize precise microstructure processing, and the diameter of the electrolyte water column (3) is relatively increased under the working condition that high resolution is not required to realize efficient large-area processing.
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