Research on the design and optimization of the cathode flow-guiding structure for electrolytic shaping machining of the small-module hard internal splines
摘要
After heat treatment, the small-module internal splines have a high surface hardness and the parts are deformed. Precision electrolytic shaping machining has good technical and economic advantages. However, the machining accuracy and surface quality are significantly affected by the flow field. To improve the uniformity of the electrolyte flow field, a design scheme for the bidirectional variable cross-section cathode flow-guiding structure was proposed. Based on the flow field simulation method, the influence of the cathode flow-guiding structure and its key dimensions on the flow field distribution was analyzed, and electrochemical machining experimental research were carried out. The simulation and experimental results show that the bidirectional variable cross-section cathode flow-guiding structure is beneficial for improving the stability of the flow field and the consistency of the velocity distribution; The cathode feed rate is 15 mm·min−1, and the tooth profile error can be controlled within 0.033 mm. When the machining depth is 50 mm, the tooth alignment error is within 0.015 mm, and the surface roughness Ra is less than 1.0 µm. The bidirectional variable cross-section cathode flow-guiding structure can meet the practical requirements of the small-module internal splines machining accuracy and surface quality, and has obvious technical and economic advantages.