Cathode Design With Flow Filed Analysis And Experimental Study On ECM Of Internal Spline

As a typical structure of special-shaped hole,internal spline is widely used in mechanical transmission,and there are many kinds of this structure.Electrochemical machining technology is better to forming the internal spline because of its high machining efficiency,no tool cathode loss and no residual stress.In order to solve the problem of low efficiency and high cost in the conventional machining of internal spline,the research on electrochemical machining of internal spline was carried out.Based on the simulation of electric field,the current density distribution in the process of electrochemical ma chining of internal spline was analyzed.Electrochemical machining system,which had ECM machine tool,power supply and electrolyte supply system.The main work and research results are summarized as follows:The basic forming law of internal spline electrochemical machining was analyzed by using electrochemical machining technology.The forming process of internal spline electrochemical machining was analyzed by ANSYS software.The problem of uneven current density distribution was solved,and better parameter combination is obtained.COMSOL software was used to analyze the velocity distribution and pressure distribution of electrolyte.According to different processing parameters,different analysis models were designed and compared one by one.Finally,t he flow field with uniform velocity and pressure distribution were obtained,and the combination of these parameters guided the cathode design.The effects of different initial machining gap,processing voltage and cathode feed rate on machining gap were studied by experiments.The results showed that the initial machining gap had almost no effect on the final machining gap;within the selected test parameters,the machining gap increased with the increase of processing voltage;under the premise of no short circuit,the machining gap decreased with the increasing of feed speed,So the faster the processing speed,the smaller the gap.The cathode structure was optimized by experiments.Finally,the better samples were obtain by the test.It was found that the tooth profile error of internal spline get better,which meets the actual requirements.