Research on precision electrochemical machining technology of the small-module internal spline

Abstract

The small-module involute internal splines have a compact structure, high surface hardness after carburization, and difficult-to-machine material properties. The adoption of PECM technology has significant technical and economic advantages. However, due to the narrow channels of the part, electrolytic products are easy to accumulate in the gap, and there are differences in the material dissolution rate at different positions of the parts, and resulting in uneven distribution of electrolyte conductivity, thereby affecting the machining accuracy. To improve the discharge efficiency of products in the machining area, the multi-physical field coupling simulation methods were used to compare and analyze the flow field characteristics corresponding to different electrolyte flow forms. The electrolyte flow form and flow field parameters were optimized to improve the flow field stability and flow velocity distribution consistency; To improve its forming accuracy, the cathode was designed based on 3D dynamic forming simulation technology, and experimental verification was carried out. The experimental results show that the machining process is stable, the tooth profile error is less than 0.033 mm, and the tooth alignment error is less than 0.015 mm. It can meet the machining technical requirements of the small-module internal splines for difficult-to-machine materials, and has significant technical and economic value.