Експериментальні дослідження електросуперфінішного оброблення сфокусованим струмом високоточних деталей авіаційного виробництва

Abstract

The object of this study is the electrochemical superfinishing of high-precision aerospace assembly components (aircraft parts) by focusing on the current. The goal is to reduce the surface and edge roughness of high-precision parts of the spool valve type in a short time (up to 10-11 minutes) by implementing the principles of superfinishing along with electrochemical processes. The task: to conduct an experiment on the simultaneous processing of all the surfaces, edges, and grooves of a test sample of a high-precision part of a spool valve type by the electrochemical superfinishing method with a focused current. Methods of research include empirical analysis of existing and widespread methods of superfinishing, full-scale experiments, and inspection. The following results were obtained. According to the analysis, it was found that there are two the most widespread operations: electrochemical processing with subsequent superfinishing of the turbine working blades and processing of holes of various shapes and sizes. It was also found that the large number of superfinishing process parameters complicates its use for complex processing of aerospace assembly components. The authors proposed an alternative method – electrochemical superfinishing, the peculiarity of which is the use of a focused current that acts directly along the part generatrix, while the part rotates at high speed around its longitudinal axis in an electrolyte. Full-scale experiments were carried out on the simultaneous processing of all surfaces, edges, and grooves of a high-precision part sample of the spool valve type by electrochemical superfinishing, and positive results were obtained: part surfaces and edges roughness was reduced. It was found that the roughness decreases more intensively during the first minute of processing, and a higher initial roughness reduces better than an initially smaller roughness. Conclusions. The scientific novelty of the obtained results is as follows: electrochemical superfinishing with a focused current has been approved on the samples of high-precision aerospace components of the spool valve type; rounding of edges, improved roughness, and removal of burrs were obtained. The proposed method of processing use is rational when there is a need for accuracy of the working surface diameters of 0.001 mm, and it can be the subject of further research.