Abstract
In order to solve the problem of uneven gap distribution and flow pattern in the complex parts with multi-stage internal cone hole in electrochemical machining, a method of computer simulation–assisted cathode design is proposed. The electric field and flow field models of machining gap are established respectively, and the simulations of different cathode profiles are carried out. When the cathode cone angle is 2°, the electric field distribution between the cathode and the workpiece is reasonable, and the electrolyte distribution in the machining gap is uniform. With the conditions of processing voltage 10 V, electrolyte inlet pressure 1.5 MPa, electrolyte temperature 28 ℃, and cathode feed speed 5 mm/min, the electrochemical machining (ECM) processing of multi-stage internal cone hole is carried out by using the optimized cathode. The results show that the surface of the workpiece has no flow pattern, the dimensional forming accuracy is better than 0.1 mm, and the surface roughness reaches Ra 0.697 μm. Research shows that the optimization of cathode structure with computer simulation can shorten the cathode development cycle and reduce the cost of cathode design effectively in ECM, which provides an efficient and feasible method for the optimization of complex cathode structure.
Highlights
As an important machining process that accounts for a large proportion of machining, about one-third of the machining volume is used for hole structure processing, which takes about a quarter of the total machining time [5]
There have been some researches on the processing methods and processes of tapered hole parts with variable cross-sections, but new processing methods for tapered hole structures with variable cross-sections of special difficult-to-machine materials are rarely involved [6,7]
Electrochemical machining (ECM) has the advantages of one-time forming, high processing efficiency, good surface quality and no loss of cathode in theory, which determines that ECM is one of the effective methods to realize the machining of conical hole structure parts [8-12]
Summary
With the rapid development of modern industry, in many fields such as aerospace, weapon equipment, biomedicine, mechanical engineering,etc. Electrochemical machining (ECM) has the advantages of one-time forming, high processing efficiency, good surface quality and no loss of cathode in theory, which determines that ECM is one of the effective methods to realize the machining of conical hole structure parts [8-12]. For the electrochemical machining of the multi-stage internal cone hole, due to the large span of the taper hole size, it is easy to cause uneven distribution of the gap between the machining gap, which affects the forming accuracy and surface quality. In order to improve the forming accuracy and surface quality of the parts, this paper uses computer simulation methods to simulate the electric field and flow field of the cathodes with different processing profiles, optimized the cathode profiles and carried out process experiments. A multi-stage internal cone hole part that meets the design requirements was processed
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