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针对目前国内汽车车身模具光整加工所存在的问题,提出了一种新型的应用光整加工技术即电化学超精密研磨技术。研制了能够实现X、Y、Z三轴直线运动和绕X、Z两轴转动的空间五自由度电化学超精密研磨数控试验机床。分析了电解时的电流密度、磨粒的种类和粒度、电解液浓度、工件与电极间的相对运动关系、超声波的有无等对工件表面粗糙度的影响。试验结果表明,使用该技术进行光整加工,可以获得表面粗糙度值Ra=0.025μm的镜面,其加工效率较普通研磨加工提高10倍以上,适合于汽车车身模具型腔的光整加工。
Aiming at the problems existing in the finishing of automobile body molds in China, a new type of ultra-precision electrochemical polishing technique is proposed. A 5-DOF electrochemical super-precision grinding NC testing machine tool was developed to realize linear movement of X, Y and Z axes and rotation around X and Z axes. The effects of current density, type and particle size of abrasive particles, electrolyte concentration, relative motion between workpiece and electrode, ultrasonic presence or absence on the surface roughness of the workpiece were analyzed. The test results show that using the technology for finishing, the surface roughness Ra = 0.025μm can be obtained. The processing efficiency is more than 10 times higher than that of ordinary grinding. It is suitable for the finishing of automobile body mold cavity.