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<p>In response to challenges of low forming accuracy in electrochemical machining (ECM) and difficulties in cathode design due to significant curvature variations in small-diameter metal screw drill stators, a design method based on multi-physical field potential gradient distribution is proposed. A mathematical model of the inter-electrode gap conductivity distribution under multi-physical fields was established, and simulations of the gap conductivity were conducted for the ECM process of small-diameter metal screw drill stators. Based on the multi-physics potential gradient distribution, a complex cathode profile was designed. The cathode profile was further optimized by integrating the energy method with the shear gradient jump, ultimately finalizing the cathode surface design for ECM. Experimental research was conducted using a large horizontal CNC electrochemical machining system developed independently. This enabled the efficient and high-quality electrochemical machining of small-diameter screw drill stators with a length of 2&#xa0;m, an inner diameter of 29&#xa0;mm, a forming accuracy better than 0.03&#xa0;mm, and a surface roughness of Ra 0.64&#xa0;μm. Research indicates that adopting the design method for the cathode profile based on multi-physics field potential gradient distribution for the cathode design in complex spiral deep-hole ECM can shorten the cathode design cycle, improve design accuracy, and effectively enhance the forming precision.</p>

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Design of cathode profile for Small-Diameter screw drill stator based on potential gradient distribution in Multi-Physical fields

  • 期刊论文

  • 发表日期：

    2026年1月5日

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  • Jiakai Zhou,
  • Chao Guo,
  • Tong Cao,
  • Jingjing Zhang,
  • Feng Yang,
  • Lin Tang

摘要

In response to challenges of low forming accuracy in electrochemical machining (ECM) and difficulties in cathode design due to significant curvature variations in small-diameter metal screw drill stators, a design method based on multi-physical field potential gradient distribution is proposed. A mathematical model of the inter-electrode gap conductivity distribution under multi-physical fields was established, and simulations of the gap conductivity were conducted for the ECM process of small-diameter metal screw drill stators. Based on the multi-physics potential gradient distribution, a complex cathode profile was designed. The cathode profile was further optimized by integrating the energy method with the shear gradient jump, ultimately finalizing the cathode surface design for ECM. Experimental research was conducted using a large horizontal CNC electrochemical machining system developed independently. This enabled the efficient and high-quality electrochemical machining of small-diameter screw drill stators with a length of 2 m, an inner diameter of 29 mm, a forming accuracy better than 0.03 mm, and a surface roughness of Ra 0.64 μm. Research indicates that adopting the design method for the cathode profile based on multi-physics field potential gradient distribution for the cathode design in complex spiral deep-hole ECM can shorten the cathode design cycle, improve design accuracy, and effectively enhance the forming precision.