Simulation And Machining System Design Of Pulse Electrochemical Deburring Of Inner Cross Hole

Hydraulic valve block simplified the design and assembly as the integrated module of hydraulic system.Since the integration,there were many processing holes in the block.The cross hole would appear due to the intersection by main channels and multiple secondary channels.Therefore deburring in high quality and effectiveness is an important research topic.For the hydraulic manufactured in bulk,the traditional processing technology for burring always have unsatisfactory performance.For the deeper position of cross hole,the contact processing such as the traditional tool or handwork could hardly operate.With the development of materials,the strength and hardness of product were increasing than before which made harder for processing method in contact type.Electrolytic processing was widely used in the processing of complex cavity and micro pore based on the corrosion principle.Applying electrochemistry to the field of burring could avoid the problem brought out by traditional methods.Electrolytic processing was a complex process which was coupled by the physical field such as temperature field,electric field and flow field.The computer simulation could be used to perform mathematical modeling based on the process of electrochemical reaction.There was an important significance for optimizing processing plan and improve the surface accuracy.In this work,the pulsed electrochemical method was used to erode the edge burrs at cross hole in hydraulic valve.By reference to electrochemical machining of blisk,the deburring cathode fixture was designed in order to improve the controllability of flow field.The flow field and electric field of machining process were analyzed by computer simulation technique.The flow path simulation was used to analyze the rationality of the fixture design,velocity and pressure distribution of electrolyte.According to the results,the electrolyte flow mode could be optimized.The mathematical model of electric field was established to analyze the influence factor of the electric field distribution and current density in order to summarize the superior parameters.The deburring efficiency and processing requirements was considered for designing the pulse power which was the key part of processing system.From the study it was shown that the burrs at the edge of cross hole were completely removed in accordance with the fixture design,the optimized machining parameters and the design of pulsed power supply.The fixture designed with simulation analysis and circuit design were proved to be rational which provided the theoretical model and foundation for the batch electrochemical removal of burr.