Cathode Design and Experimental Study of NC Electrochemical Boring Processes for Stepped Holes

Abstract

Abstract: NC electrochemical boring method was adopted to solve the processing problems of stepped inner holes with small inlet,large inner cavity,and large deep diameter ratio.According to the structural characteristics of stepped holes,cathodes with different spiral outlets,different rotating angles,and different taper of shunt blocks were designed.The flow fields were analyzed by FLUENT,and the results show that the cathodes with 24° conical angle,360° rotating angle,and double spiral outlets meet the design requirements.Orthogonal tests were carried out to study the influences of processing parameters on removal amount and processing clearance.Main size of the cathode is determined by the testing results,and the problems of uneven wall thickness of the stepped hole are solved by correcting the tapers of the cathodes.By the proposed method,errors of the stepped hole are small,and quality of processing surfaces is good,which meet the production requirements.

Key words: electrochemical machining, boring；flow field, orthogonal test, stepped hole

摘要：

采用数控电解镗孔的方法,解决了进口小、内腔大、深径比较大的阶梯内孔的加工难题。根据阶梯孔的结构特点,设计了不同数量的螺旋形出液口、不同旋转角和不同分流块锥度的阴极,应用FLUENT分析了各流场的优劣,得出24°锥角、360°旋转角、双螺旋出液口阴极满足设计要求的结论。通过正交试验研究了加工参数对去除量和加工间隙的影响规律,根据试验结果确定了阴极主要尺寸,并通过修正阴极锥度解决了阶梯孔壁厚不均的问题。采用此方法加工的阶梯孔内孔误差小、加工面质量好,满足生产要求。

关键词: 电解加工, 镗孔, 流场, 正交试验, 阶梯孔

CLC Number:

TG662

XU Bo1,2;GAN Weimin1,2;HE Yafeng1,2;LI Wenjing3;WANG Xiangzhi1,2 . Cathode Design and Experimental Study of NC Electrochemical Boring Processes for Stepped Holes[J]. China Mechanical Engineering.

徐波1,2;干为民1,2;何亚峰1,2;李文静3;王祥志1,2. 阶梯孔数控电解镗孔加工的阴极设计及试验研究[J]. 中国机械工程.

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