Optimization and Experiments of Flow-guiding Structure of Cathode in Electrochemical Machining of Internal Splines

doi:10.3969/j.issn.1004-132X.2025.11.022

Abstract

Abstract:

Due to the complex profile and space limitations of involute internal splines， the uniformity of the flow field was difficult to control， which in turn made it difficult to improve the processing accuracy during electrochemical machining. The electrolyte flow mode， flow channel structure and processing mode were analyzed， a cathode flow guide structure was designed， and flow field analyses were conducted based on simulation platform. The results show that the inlet and outlet flow guide structure may eliminate flow field defects such as vortices， significantly increase the electrolyte flow rate in processing areas， and meet the requirements of electrochemical machining of involute internal splines. Processing experiments were carried out using the inlet and outlet flow guide structure. The machining processes are stable， the workpiece surface is bright and clean without marks， the roughness value Ra is as 0.8 μm， and the internal spline accuracy reaches level 5， verifying the rationality of the flow guide structure.

Key words: electrochemical machining, involute internal spline, flow-guiding structure, flow field design, processing stability

摘要：

渐开线内花键由于型面复杂、空间受限等原因，流场的均匀性不易控制，导致电解加工时精度难以提高。针对电解液流动方式、流道结构、加工模式进行分析，设计了阴极导流结构，并基于仿真平台进行流场分析。结果表明，进出液导流结构能够消除涡流等流场缺陷，显著提高加工区的电解液流速，满足渐开线内花键电解整形加工需求。采用进出液导流结构开展加工试验，加工过程稳定，工件表面光亮整洁无流痕，粗糙度Ra可达0.8 μm，内花键精度达5级，验证了导流结构的合理性。

关键词: 电解整形加工, 渐开线内花键, 导流结构, 流场设计, 加工稳定性

CLC Number:

TH131.4

Yang LI, Hongyu WEI. Optimization and Experiments of Flow-guiding Structure of Cathode in Electrochemical Machining of Internal Splines[J]. China Mechanical Engineering, 2025, 36(11): 2658-2664.

李阳, 韦红余. 内花键电解整形阴极导流结构优化与试验[J]. 中国机械工程, 2025, 36(11): 2658-2664.

Figures/Tables 17

Fig.1 Schematic diagram of internal spline electrochemical machining

Fig.2 Involute internal spline test specimen

Fig.3 Schematic diagram of central feed electrolyte flow

Fig.4 Schematic diagram of different flow-guiding structures

Fig.5 Flow channel structural model

Fig.6 Electrolyte flow velocity distribution diagram （without flow-guiding structure）

Fig.7 Electrolyte flow velocity distribution diagram （inlet flow-guiding structure）

Fig.8 Electrolyte flow velocity distribution diagram （inlet and outlet flow-guiding structure）

Fig.9 Streamline distribution diagrams for three types of flow-guiding structures

Fig.10 Hardened internal spline blank

Tab.1 Main geometric dimensions and precision requirements for splines

齿形公差/

Fig.11 Internal spline shaping electrochemical machining test rig

Tab.2 Test parameters

参数	数值
初始加工间隙/mm	0.2
阴极进给速度/（mm·min^-1）	15
加工电压/V	30
电解液温度/℃	25
电解液电导率/（S·m^-1）	8.1
电解液入口压力/MPa	1.2
电解液出口压力/MPa	0.2

Fig.12 Tooth groove morphology of specimens with different flow-guiding structures

Tab.3 Surface roughness of specimens with different flow-guiding structures

试件	粗糙度Ra实测值
无导流结构试件	1.1
进液导流结构试件	0.8
进出液导流结构试件	0.6

Fig.13 Current variation curve during electrochemical machining of internal splines

Tab.4 Test specimen machining measurement results

测量项目	要求值	实测值
齿形误差/mm	0.03	0.02
齿向误差/mm	0.013	0.01
齿距累积误差/mm	0.039	0.02
齿面粗糙度Ra/μm	1.6	0.4
实际齿槽宽/mm	1.64～1.71	1.68
齿根过渡圆弧/mm	R0.2最小	R0.4

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