Research On Technological Experiments And Simulation Of Numerical Control Electrochemical Machining

Numerical control electrochemical machining is a new type of electrochemical machining technology. In order to form the anode surface, this technology uses the cathode with 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.In electrochemical machining process, the anode surface machining quality and precision are affected by many factors (electrolyte conductivity, current density, operating voltage, the cathode feed rate, 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 and the accurate analysis of anode surface can be obtained through the simulation of numerical control electrochemical machining process.The main work done in this paper is as follows:1. Three basic theories that the electrochemical anodic dissolution theory, electric field theory and the flow field theory are generally summarized and the experimental equipment are also briefly introduced in this paper.2. The basic technological experiments are carried out by using a cathode with straight edge. The technology law of numerical control electrochemical machining, the prior effect of technological parameters on the experiment-indicator, the optimal combination of technological parameters and the significant impact of technological parameters to experiment-indicator are obtained through the technological experiments. These analysis provide reference to choose technological parameters for involute surface machining.3. The prediction of the anode surface can be achieved through electric field simulation using finite element analysis. Theoretical and measured values are compared to verify the accuracy of the electric field model. 4. The involute surface is machined through choosing reasonable technological parameters. The shape error of after theoretical and actual machining is calculated to analyze the machining accuracy of the involute surface, and the surface quality is also made a brief analysis.