小孔径内壁螺旋形结构电解加工试验研究

以小孔内壁为加工对象,设计螺旋型刃阴极,研究电解加工小孔径内壁螺旋形结构成形规律。分析了小孔径内壁螺旋槽电解加工成形基本理论,设计并制作了螺旋形阴极;基于ANSYS软件进行电场仿真,分析不同加工间隙和电压时的电场分布情况;利用FLUENT软件分析不同初始加工间隙时的流场分布情况,通过流场分析优化了阴极结构,解决了由于存在涡流现象导致加工质量差的问题;通过正交试验分析各参数对加工结果的影响规律。采用优化参数加工所得螺旋槽最大深度为0.672 mm,误差为0.017 mm,表明数控电解加工小孔径内壁螺旋形结构切实可行。

Experimental Research on Electrochemical Machining of Spiral Structure with Small Aperture Inner Wall

Taking the inner wall of the small hole as a processing object,a spiral edge cathode was designed and the forming rule of the spiral structure of the inner wall of the small hole was studied by electrochemical machining.Firstly,the basic theories of ECM forming of spiral grooves with small-aperture inner walls are analyzed,and the spiral cathodes are designed and manufactured.The electric field simulation based on ANSYS software is used to analyze the electric field distribution at different machining gaps and voltages.The flow field distribution in different initial machining gaps is analyzed using FLUENT software,the cathode structure was optimized by flow field analysis,and the problem of poor processing quality due to the eddy current phenomenon was solved.Finally,the influence rule of parameters on the results was analyzed by orthogonal experiments.The depth and error of the spiral groove processed by the optimized parameters are 0.672 mm and 0.017 mm,which indicates that the numerical control ECM of the spiral structure with a small aperture on the inner wall is feasible.