Modeling And Experimental Study On The Electrochemical Machining Of Rotary Parts By The Suspended Cathode

With the development of mechanical products and science technology,high-quality parts urgently require improving macro-forming accuracy and surface roughness.Electrochemical finishing has high leveling efficiency,good leveling quality,and processing from the hardness of the material constraints and many other advantages.Electrochemical processing of the finishing process can achieve the improvement of macro-forming accuracy,which for high-quality parts of the acquisition is of great significance.The key to improving the accuracy of electrochemical machining is to reduce the inter-electrode gap and increase the angle of the cathode on the surface of the part.The stability of the inter-electrode gap in the electrochemical machining is affected by the electric field,the flow field and the work-piece speed,and the change of the inter-electrode gap also affects the electric field and the flow field in the inter-electrode gap.At present the electrochemical machining,the formation and control of the inter-electrode gap is completed by the mechanical action.However,the detection and control of the inter-electrode gap is more accurate for the determination method and the sensitivity of the detection device is higher on the premise that machine in the small inter-electrode gap.However,due to the relatively poor electrochemical machining environment,the existing method of forming,detection and regulation of inter-electrode gap are difficult.Therefore,the electrochemical machining of suspended cathodes is proposed in this paper.Suspension cathode electrochemical machining forms a stable inter-electrode gap by means of cathodic suspension.Using the electrolyte into the cathode to form a liquid film between the anode and cathode,the balance between the liquid film produces the support force and the gravity of the cathode itself achieve the cathode suspended in the work-piece surface.Compared with the conventional method of mechanical positioning and control of the cathode in the electrochemical machining,the advantages are:1)By changing the flow of electrolyte can control the processing gap,in the small gap conditions,the gap is simple to control and is conducive to the formation of small gaps;2)During the processing the cathode feed to the anode surface with the anode material removed real-time is conducive to the stability of the gap conditions to achieve processing;3)Through the cathode suspension processing methods to avoid the work-piece positioning error to the processing error transmission.On the basis of suspended cathode,the effect of electrochemical effect on the machining efficiency of the work-piece is enhanced by increasing the angle of the cathode on the anode surface.The main contents of this paper are as follows:the gap modeling problem is further studied on the basis of the work of Cai Xiao,a graduate student in this laboratory,the gap theoretical model of suspended cathode electrochemical machining rotary parts is revised and the experimental model is verified;building experiment roof of the suspension cathode electrochemical machining rotary;the single factor experiment is designed to obtain the optimal processing parameters;design experiments of the different package angle of the cathode processing rotary parts,the effects of different angle on the machining accuracy and surface quality are investigated,the study found that increase the angle of the cathode on the anode surface can improve the surface quality of the rotary parts and processing accuracy.