Abstract:

For the structure characteristics and machining difficulties of lightweight stepped hole with big inside and small outside, a fixed cathode electrochemical machining method was proposed to realize the inner hole machining. Taking the center stepped hole on rotation shaft of an airplane landing gear for example，in order to improve the machining quality and efficiency, the cathode structure was optimized firstly based on numerical analysis and experimental verification. Stepped variable voltage machining method was proposed which met the actual production needs. Based on the above, taper of cathode was modified and experiments were conducted. Finally, passable products were manufactured and the process is stable, which can meet the requirements of mass process.

Key words: stepped hole, electrochemical machining, fixed cathode, numerical analysis, stepped voltage

摘要：

针对内大外小轻量化阶梯孔结构特点与加工难点，采用固定阴极电解加工方式实现其内孔加工。以某飞机起落架转轴中心阶梯孔为例，为提高其加工质量及加工效率，基于数值分析和试验验证的方法优化了阴极结构，结合实际生产需要，提出了阶梯式变电压加工方法。在上述基础上修正阴极锥度并进行工艺试验，最终加工出合格件，该方法加工质量稳定，满足批量生产需要。

关键词: 阶梯孔, 电解加工, 固定阴极, 数值分析, 阶梯式电压