电解加工锥式变齿阴极设计及试验

Design and Experiment of Conical Variable Tooth Cathode in Electrochemical Machining

为了解决传统阴极相邻等厚齿间电解液流场出现分散、不饱满和漩涡问题,基于电解加工蚀除规律,设计一种锥式变齿,利用COMSOL Multiphysics对加工间隙流场分布进行模拟,对齿牙进行修形。仿真结果表明:在每片厚轮齿一侧切除1/2,旋出台阶均为0.3 mm的圆角,另一侧的薄齿旋出台阶右下角为0.4 mm的圆角,有效降低工作齿错位形成的台阶对流场的影响。采用锥式变齿阴极进行相关试验,对加工成型后多旋线工件切片进行测量分析,结果表明锥式阴极满足设计要求,极大地提高了加工精度和加工效率。

To solve the problems of cavitation, not full and vortex in machining electrolytic flow field between adjacent working tooth, the conical variable teeth are designed based on the etching law of electrochemical machining. By COMSOL Multiphysic, the distribution of the gap flow field is simulated and tooth shape is optimized. The simulation result shows that by cutting off 1/2 of every piece thick tooth on one side, its round angle radius of spiraled steps is within 0.3 mm, while the lower right corner on the other side within 0.4 mm, which effectively reduces the influence on gap flow field from the steps caused by working tooth malposition. The cone type variable teeth cathode is used to carry out relevant tests, and the multi rotation line workpiece slices are measured and analyzed. The results show that the conical cathode meets the design requirements and greatly improves the machining accuracy and efficiency.