膛线电解加工仿生阴极工作齿设计与研究

Design and Research of Bionic Cathode Working Teeth for Rifling Electromachining

为解决膛线阴极相邻齿间电解液流场出现分散、不饱满和漩涡造成阴极烧伤、加工效率低的问题,根据仿生表面减阻机制,设计不同参数分布的仿生结构的工作齿,利用COMSOL仿真分析了仿生结构的形状参数与电解液流速、湍流参数和剪切速率的关系。结果表明:工作齿表面仿生尺寸为s=0.2 mm、h=0.05 mm的仿生结构不仅可以减小摩擦阻力,而且可以有效地稳定间隙流场。采用仿生阴极进行电解加工试验,对加工成型后切片进行测量分析,结果表明:仿生结构阴极满足设计要求,零件的加工精度得到保证。

In order to solve the problems of cathodic burn and low processing efficiency caused by dispersion,underfill and vortex in the electrolyte flow field between adjacent teeth of the rifling cathode,the working teeth with different size riblet surface were designed in terms of the theory of drag-reduction of riblet surface to optimize teeth shape and the gap flow field further.The gap flow field was simulated based on the COMSOL multiphysics.The influence of the shape parameter of riblet surface upon the velocity,turbulence parameter and shear rate were discussed.It is proved that the riblet surface size likes s=0.2 mm,h=0.05 mm of the working tooth not only can reduce the friction,but also can stabilize the gap flow field.The ridged biomimetic structure cathode was used to conduct relevant electrolytic machining experiments,and the slices of the breeched workpiece were measured and analyzed.The results show that the ridged biomimetic structure cathode meets the design requirements and the machining accuracy of the parts is guaranteed.