| 摘要: | 本研究提出以精密電化學加工(Precision Electrochemical Machining, PECM)取代傳統CNC加工製造渦卷式壓縮機轉子，並建立完整之製程規劃。依轉子幾何外形與極間間隙設計工具電極，並採絕緣覆層消除加工時之雜散電流。為確保電解液於微小加工間隙中均勻更新，電極內部設置流道並施加低頻微振動，以加速反應產物排除、抑制氧化膜生成及避免短路。
其次利用電腦模擬流場軟體Autodesk CFD 2024，對建立的多個動、靜渦卷加工流場模型進行分析以及調整電解液流場。本研究建立之流程與參數對於渦卷轉子製造提供可重複複製性，並可延伸應用至其他複雜曲面零件，如離心渦輪、燃油泵葉輪等。
電化學加工方面，本研究探討了不同入口壓力以及進給速度對動渦卷及靜渦卷之齒型偏差量、壁面傾斜度與表面粗糙度。在動渦卷部分，以入口壓力8 bar、進給速度0.15 mm/min下，加工時間為92分鐘，齒型偏差量-0.255 mm ~ 0.352 mm，壁面傾斜度0.008° ~ 0.458°，側壁表面粗糙度Sa 0.217 μm。靜渦卷以入口壓力6 bar、進給速度0.1 mm/min，加工時間為138分鐘，齒型偏差量為 -0.034 mm ~ 0.684 mm，壁面傾斜度0.016°~0.262°，側壁表面粗糙度Sa 0.168 μm。
;This study proposes replacing conventional CNC machining with Precision Electrochemical Machining (PECM) to manufacture scroll compressor rotors, and establishes a complete process plan. Based on the rotor geometry and the designed interelectrode gap, a dedicated tool electrode was developed, and an insulating coating was applied to eliminate stray currents during machining. To ensure uniform electrolyte renewal within the micro-scale machining gap, internal flow channels were integrated into the electrode and low-frequency micro-vibration was introduced to accelerate removal of reaction products, suppress oxide-film formation, and prevent short-circuiting.
In addition, Autodesk CFD 2024 was used to analyze multiple flow-field models for machining both the orbiting and fixed scrolls, and to iteratively optimize the electrolyte flow distribution. The developed workflow and process parameters provide a repeatable and reproducible manufacturing route for scroll rotors, and can be extended to other complex freeform components such as centrifugal turbines and fuel-pump impellers.
From the PECM experiments, this study investigated the effects of inlet pressure and feed rate on profile deviation, wall inclination, and surface roughness for both orbiting and fixed scrolls. For the orbiting scroll, under an inlet pressure of 8 bar and a feed rate of 0.15 mm/min, the machining time was 92 min; the profile deviation ranged from −0.255 mm to 0.352 mm, the wall inclination ranged from 0.008° to 0.458°, and the wall surface roughness is Sa 0.217 μm. For the fixed scroll, under an inlet pressure of 6 bar and a feed rate of 0.10 mm/min, the machining time was 138 min; the profile deviation ranged from −0.034 mm to 0.684 mm, the wall inclination ranged from 0.016° to 0.262°, and the wall surface roughness is Sa 0.168 μm. |
