Simulation And Experimental Research On Electrochemical Deburring Of Inner Cross Hole

Due to the characteristics of machining,the existence of a large number of burrs on surface of machining workpiece is inevitable.It not only has a big effect on precision,but also seriously affects the quality and performance of parts.The main method of deburring is mechanical method at the present stage.With the increasingly complex structure and high quality standards,the mechanical deburring cannot meet the requirements of processing quality,efficiency and cost.Electrochemical machining can be applied to a variety of conductive materials regardless of hardness and toughness because of its non-contact processing without generating residual stress.Especially in the position that conventional mechanical processing is difficult to reach,such as the complex shape of slender shell,deep hole and inner cross hole electrochemical deburring is more to highlight its advantages.Electrochemical machining is a complex reaction process,which is affected by the interaction of electric field,flow field,temperature field and so on.In order to achieve an expected machining effect,machining parameters selection usually depends on experience and require repeated experiments.Computer simulation technology provides a theoretical basis for the processing scheme and parameters selection and cathode and fixture design.It has an important significance to shorten the processing cycle and improve the quality and efficiency of electrochemical machining.The basic principle and process of electrochemical machining are introduced in this paper,and the characteristics of flow field and electric field in electrochemical machining are analyzed.The flow field distribution of electrolyte is simulated based on the theory of computational fluid dynamics.The distribution of flow velocity and pressure under various conditions is analyzed.According to the machining gap flow distribution,processing scheme selection and cathode fixture is determined.Electric field models of different electrode shapes are established and the contour curve of the workpiece in the process of machining is obtained by solving the simulation model.The effect of machining voltage,processing time and other parameters on deburring are analyzed to select the final experimental parameters of machining.Finally,the experimental platform of electrochemical machining is set up and the accuracy of the simulation model is verified by the experimental results of electrochemical deburring using the inner cross hole of the valve sleeve.The results of the study show that the burrs on the workpiece surface are completely removed according to the simulation results of the proposed optimal to burr processing parameters,and the edge forms chamfer which agree well with the simulation results.It is proved that the simulation model can accurately predict the burr removal process,which can provide a theoretical basis for the development of the electrochemical deburring scheme and the reasonable choice of parameters.