Research On Large Aspect Ratio Narrow Groove Electrochemical Milling Technology

With the advancement of technology,more and more narrow-groove structures with complex shapes have emerged in key components in the medical machinery,aerospace,aerospace,automotive manufacturing industries.These narrow trenches generally have the characteristics of small structural size,large aspect ratio and large depth and width.For such structures,conventional machining methods such as mechanical cutting,grinding,and special machining EDM cannot perform effective high-quality and high-efficiency machining.The electrochemical processing technology is a copy processing process using the principle of anodic dissolution,which has the advantages of high efficiency,high quality surface,no loss of electrodes,and is not affected by the hardness of materials.It has unique advantages that traditional processing and other special processing technologies do not have.In this paper,a new technology for electrochemical milling using tube electrode is proposed for the processing problem of large aspect ratio closed narrow groove blind groove.This technique is a method of performing electrochemical milling using a tubular electrode as a tool cathode.The specific research contents are as follows:1.Theoretical analysis of tube electrode electrochemical milling.The basic characteristics and principles of electrochemical machining are expounded.The basic principles and characteristics of electrochemical milling of tube electrodes are summarized.For the special processing of narrow-groove structural parts,a step-by-step processing model for electrochemical milling of tube electrodes is established.Theoretically,the influencing factors of machining stability and the influencing factors of machining precision of the narrow groove of tube electrode electrochemical milling are analyzed,which lays a theoretical foundation for the subsequent process parameter test.2.Flow field simulation and electric field simulation of tube electrode electrochemical milling.Firstly,the influence of pipe diameter and different nozzle structure on the machining state is analyzed.Using the comsol simulation software,the modeling and simulation of the machining gap flow field were carried out from the wall thickness,the pipe diameter and the electrolyte pressure of the tube electrode,and the process test of the tube electrode as the tool cathode of the electrochemical processing was theoretically verified.3.A new processing technology for large-width-closed narrow-groove blind groove structure--electrode milling of tube electrode was tested.The parameters such as the voltage amplitude between the cathode anode,the frequency of the electrolysis power supply,the duty ratio of the electrolysis power supply,the influence of the cathode diameter,the electrolyte pressure and the feed speed of the tube electrode on the process test results were analyzed.By optimizing the parameters,a large aspect ratio closed narrow groove blind groove structure with high shape accuracy,high surface quality and good contour consistency is processed.4.Install the tube electrode on the rotating shaft,carry out the process test of the rotary tube electrode electrochemical milling of the narrow groove,coMPare and analyze with the results of the non-rotating electrochemical milling,and study the processing results of different electrode speeds on the narrow groove and the processing stability.On the basis of the optimized parameters,the complex curved narrow groove pattern structure is subjected to electrochemical rotary milling,and the curve-shaped large aspect ratio closed narrow groove pattern with good consistency,steep sidewalls and complicated shape is successfully processed.