自动化电解去内交叉孔毛刺过程的仿真与实验

针对零件内部交叉孔相贯线处的毛刺去除困难的现状,利用电解加工的原理,采用插孔固定阴极式的电极布局形式,提出基于电流检测的自动电解去毛刺的方法.建立电解去毛刺的数学模型,用仿真和实验研究电解去毛刺过程中加工间隙、加工电压及加工时间对毛刺去除的影响,分析去毛刺过程中电流密度随时间的变化规律.在该电极布局形式下,毛刺与工件间的平均电流随着毛刺的去除逐渐下降,且电流曲线的斜率在毛刺完全去除后趋近于0.以此作为去除过程是否完成的判断依据,研制了自动电解去毛刺的控制系统并完成了自动化去毛刺实验.实验结果表明:该方法能够有效地对毛刺大小进行判断,可以控制加工时间进行精确的毛刺去除,成本低、安全可靠.

Simulation and experiment of automatic electrolytic deburring on inner intersecting holes based on electric current detection

Aiming at the great hardship and low efficiency of deburring on the inner intersecting holes, using electrolytic machining theory and applying fixed inserting cathode pole layout, an automatic electrolytic deburring method based on detection of electric current is proposed, and a mathematic model is set up. Simulation and experiment are adopted to find out the effect of gab, voltage and time in the electrolytic deburring process. The result shows that the electric current density changes over time. Under the present pole layout condition, the average electric current goes down and the slope nearly reaches zero when deburring is completed. Taking this as the judgement of end of deburring, an automatic electrolysis deburring control system is developed. The experiment shows that the method can control the machining time according to the size of burr and remove it accurately. Besides the method has low cost and high quality.