Applied Fundamental Research On Electrochemical Grinding Of Complex End Surface

With the development of the society and the high technology, complex surfaces are more widely applied and requirements of their quality are stricter. The higher requirements depend on follows: For one thing, the products are needed to meet some special requirements like tribology, mechanical properties and function. For another, the products are required to meet aesthetic appearance and people's demand for product appearance. Electrochemical grinding is suitable for complex surface precision and efficiency machining as its high processing quality, high efficiency, no grinding burns, burrs and cracks and little wheel wear. However, influence factors of ECG are numerous and influence law of processing quality is complex. So process developments for different objects are necessary.Based on the ECG of the shaver cap's inner flat surface, the ECG equipment is developed and fixture and grinding head are designed. Experimental research on precision ECG of the shaver cap's inner flat surface based on independently developed equipment is carried out. Primary research contents including:1. In order to improve the machining quality and accuracy, the ECG machining system is built, including the main structure design and electrolyte circulation filtering system design which ensure the stability of the machining.2. Based on the characteristics and process law of ECG, the structure of grinding head is design and abrasive granularity and caps material hardness are optimized. According to the contrast experiment of different abrasive granularities and caps material harnesses, based on the analysis of grinding head consumption, abrasive granularity and caps material hardness suit for the shaver cap's inner flat surface ECG are determined.3. Fixture optimization based on electric field simulation and experimental verification. In order to resolve the problem of poor machining localization, influence of fixture's positioning unit insulation to the current density distribution in the gap is studied by electric field simulation. Experimental research which studies the influence of positioning unit insulation to machining current, flatness of inner flat surface and edge fillet of through multi-grooves in the inner flat surface is carried out. Consequently, machining accuracy and repeated machining accuracy of ECG are improved.4. Based on the theoretical analysis, processing experimental research of the shaver cap's inner flat surface ECG is carried out on independently developed equipment. According to processing experiment, influence of translational method, translational amount and translational times to the roughness and flatness of the shaver cap's inner flat surface is researched and small batch processing is realized with optimized parameters.With independently develop ECG equipment, ECG on the shaver cap's inner flat surface is carried out. Shaver caps with roughness below 0.3?m and flatness between 3~5?m are stably manufactured which guarantee the small batch production.