The Cathode Design Of Gear Electrolytic Deburring And The Study Of The Distribution Of The Electric Field And Flow Field

Electrochemical machining technology gradually become one of the importantmeans of manufacturing technology for its high production efficiency,good quality ofmachined surface,no stress loss,no tools loss and other advantages.Its application rangeis gradually expanding.The application of the electrochemical deburring is developingfast and is widely used.But because the methods of cathode design are not perfect,andelectrochemical machining is influenced by many factors, such as electric field, theflow field,thermal field and machining gap.These bring some obstacles to theapplication of electrochemical machining.With the development of computertechnology,and the theory of electrochemical machining continues to mature，computersimulation method has been applied to the cathode design and the analysis of profilerules.Based on the theories of electrochemical machining,this paper analyzes thedistribution of electric field for fixed cathode,which is involved in electrochemicaldeburring of gear shaft.On these basis,the three-dimensional model was simplified to atwo-dimensional.Using the finite element numerical method and combining with thecorresponding analysis software,the potential distribution in the gap has beenanalyzed.The results of the analysis show that there are many equipotential lines in thegap and each equipotential line can be used as a negative pole boundary.According toone of the equipotential lines,the paper use curve fitting method to generate atwo-dimensional surface of cathode.To improve the precision of the cathode design,anew method to remedy the cathode is proposed,which is based on the Space Fouriertransform and spatial transfer function.Secondly,combining with the fluid field analysissoftware,the paper analyzes the pressure and flow rate of electrolyte in two different flow patterns.By analyzing the results,a suitable electrolyte flow pattern has beendemonstrated.In all factors,which affect removing rate and removal amount ofworkpiece,current density is the main factor.So it mainly discussed the influence ofprocessing parameters on the current density,and these influence has been validated byexperiments.Then the paper discussed the influence on entire electrolysis processingaccuracy and processing quality.Cathode design with FEM not only improves the convergence of calculation andgets more precise results,but also supplies with a computer-aided-cathode-designmethod,which may bring a wide application prospect for the precision electrolyticmachining of parts with complicated profile. At the same time,through the calculationand analysis of the above,the paper provide certain theoretical guidance for selection ofreasonable electrolytic liquid flow mode and electrochemical machining parameters.