To improve the machining effect of ZrO2 insulating ceramic as thermal barrier coatings (TBCs) on aeroengine turbine blades,machining experiments were carried out to explore the influence of different machining gaps on machining stability and efficiency in spark assisted chemical engraving (SACE) process. An electrode-alignment method was presented for giving a machining gap by use of image observation based on a charge coupled device ,and the tests showed that the gap accuracy can be controlled within ±1 μm. Further,several experiments were conducted to evaluate and optimize the machining gap with specific processing parameters. The methods of ion sputtering and Matlab image processing were adopted to analyze removal areas from workpieces ,and the range of optimum machining gap was gained according to the maximum removal area come from stable sparks. This research can provide the basis for optimizing SACE process.%面向航空发动机涡轮叶片热障涂层ZrO2陶瓷绝缘材料的加工,开展了不同加工间隙对加工稳定性及效率影响的实验研究.采用CCD图像在线观测微观接触的对准电极方法,实现了加工间隙测量给定精度可控±1μm,进而在特定工艺参数下实验研究了加工间隙的评价和优化,利用工件表面离子溅射镀膜和Matlab图像处理技术实现蚀除量分析,得出了稳定加工时材料最大蚀除量的最佳加工间隙范围,为电火花放电辅助化学加工工艺优化提供了依据.
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