Experimental Study On Numerical Control Electrochemical Turning

Numerical Control Electrochemical Turning (NC-ECT) is a new type of electrochemical machining technology for rotary ones made from hard-to-machine materials. In order to form the anode surface, this technology uses the cathode with a simple shape to do contour evolutional motion according to numerical control instructions. This machining process not only has the flexibility of CNC, but also has the advantage of electrochemical machining. By using NC-ECT, we can machine shaft and cam type components. And in the processing, the parts have no residual stress, so it has good surface quality.In electrochemical turning process, there are many factors to affect the anode surface machining quality and precision, such as current density, initial inter-electrode gap, operating voltage, the processing parts speed, etc. Therefore, how to choose a combination of process parameters to meet the machining requirements is critical important in the actual production and the choice of process parameters is often achieved through the technological experiments. In addition, the prediction of the anode surface and the accurate analysis of the effect about various factors to anode surface can be both achieved through the simulation of numerical control electrochemical turning process.The main work has been done in this paper is as follows:1. The basic theory of electrochemical turning is generally analyzed and the experimental equipments are also briefly introduced in this paper.2. The cathode for ECT is designed. The simulation of fluid field during ECT processes is done by the software of computational fluid dynamic (Fluent). Through the contrast analysis, the more reasonable cathode is designed and its rationality is proved through contrastive experiments.3. The electrochemical turning machining test was carried out and the effect of machining parameters on the ECT is investigated. 4. The prediction of the anode surface can be achieved through electric simulation using finite element analysis. Theoretical and measured values are compared to verify the accuracy of the electric field model.