The Cathode Design And Experiments Of Electrochemical Machining Deburring

All kinds of the sharp corners, edges and other irregular burrs (especially the intersecting pinhole) are produced in parts surface of the machining process. Although burrs are small, the hazards caused by burrs are very large. At present, manual and mechanical methods are used for deburring in many occasions. They are time-consuming and difficult to ensure the quality of deburring. For the above problems, the cathode design and experiments of ECM machining deburring is researched in this paper.According to mechanical processing of the intersecting pinhole in the deburring, the cathode of ECM deburring is designed and the CFD and ANSYS softwares are used in ECM to study the2D flow field and electric field of internal cathode which is guide the problem of designing cathode.The main contents as follows:(1) Based on ECM method, the intersecting pinhole burr which is formed with45steel drilling is used, the cathode of the ECM deburring is designed;(2) Based on computational fluid dynamics (CFD), three conditions are researched and they are without cathode, the multihole outlets with cathode and the single-hole outlet with cathode. Flow field simulation of ECM is studied though by means of the picture of the flow rate and perssure. The rationality scheme of electrolyte flow direction is confirmed;(3) Based on finite element method (FEM), the voltage model of the ECM deburring is built, the contour curve of the intersecting pinhole ECM deburring is gotten by way of analysis solvers. The voltage, machining gap and time parameters are analyzed which are affected in ECM deburring;(4) Based on the intersecting pinhole on the single factor of ECM deburring experiments, the contour curve of different voltages, machining gaps and times are observed which is used the better effect cathode, the simulation results and the test results are analysed, the FEM model of accuracy is verified.