Basic Experimental Research On Electroforming Of Thin-walled Concave And Convex Structure

With the development of aviation technology, aviation products become thin-walled, integrated and complicated. Thin-walled parts with its advantages such as light quality, high strength, have been widely applied in aviation productions. Traditional processing is difficult to ensure the design requirements of the thin-walled parts dimensional accuracy, shape accuracy and etc. The electroforming technology as a kind of additive fabricator of special processing technology has unique advantage in electroforming thin-walled parts, and can avoid the problem of traditional processing. Therefore, this paper will focus on thin-walled concave and convex structure parts to research on electroforming experiment of these parts.Aiming at the anode design of thin walled concave structure and thin walled convex structure electroforming, this paper puts forward a method of electroforming anode optimization design by using ANSYS. In the process of optimizing the anode profile, under the small gap between the cathode and anode, the control node of the anode is adjusted according to the electric field intensity of the electric field. Using the method to optimize the anode profile can improve the uniformity of the cathode surface electric field distribution. In electroforming test, the electroforming test piece thickness distribution trend is consistent with the optimized cathode electric field intensity distribution trend. Thus this electroforming test verifies the effectiveness of the proposed method for the optimization design of anode.For the anode design of thin-walled concave and convex structure electroforming, this paper proposes a design method of electroforming Insoluble combined anode. First, get the optimized profiles of thin walled concave structure and thin walled convex structure electroforming. And then, combine the optimized profiles. Eventually, the insoluble combined anode profile is formed. Using this method to optimize the design of anode, the optimized profile makes the cathode electric field intensity ratio of the maximum and minimum values decrease from 3.04 to 1.20.In this paper, the test device for electroforming of thin-walled concave and convex structure is designed. Use hollow-type insoluble combined anode, and combine the cathode translation slightly. It is theoretically and experimentally shown that the method of anode design is effective by the comparison test.This paper designs a kind of apparatus using ion-exchange membrane eletrolyzer to supply Ni2+ to the solution, and conducts the electrolysis experiment by using this device. Research on the influence of the current density on anode nickel dissolved quality, anode dissolved efficiency, and the influence of the distance between the cathode and anode,and the factors affecting stability of electrolytic nickel in electrolytic cell. Then, this ion-exchange membrane eletrolyzer combines electroforming cell to form a set of Ni2+ supplement device. And the electroforming experiment is conducted. Through the comparison of the anode nickel dissolution quality with the cathode nickel deposit quality, this paper researches on the Ni2+ concentration in the solution. The results show that to maintain dynamic balance of Ni2+ concentration condition is that the electrolytic cell current is equal to the electroforming cell current.