| Spherical cathode numerical controlled electrochemical contour evolution machining is a new manufacturing technology which uses a simple ball-shaped cathode as a pass fluid electrode and then does multi-dimensional motion driven by CNC system. It has both the flexible of CNC machining and the advantages of electrochemical machining, and it can effectively work out the problems in machining complex-shaped components which were difficult to cut.In this paper, under the guidance of the above-mentioned ideas, a numerical control electrolysis machine experimental set-up was developed and the spherical cathode electrochemical machining experiments were done in this experimental set-up.Based on the base of an ordinary vertical milling machine, by designing appropriate electrolyte system and matching applicable control system, five-axis CNC Electrochemical Machining has been achieved successfully. The transformation of mechanical body include the design of X, Y, Z three parallel movement axis, B to the swing table and C to the rotary table, as well as the selection of servo motor for axis.The spherical cathode was adopted for its wide adaptability and greater flexibility. Three kinds of spherical cathodes were designed according to cathode design theory, and electric field analysis by ANSYS was conducted respectively. Finally, the most suitable spherical cathode was chosen through experiments, the results of the analysis of the electric field were verified as well.Spherical cathode multi-factor orthogonal experiment was finished in the electrolysis machine experimental set-up. The analysis of the test described the affect of surface roughness and cutting depth by various factors and identified the optimal parameter combination of surface roughness, which laid the foundation for complex surface machining.Sphere and the circular surface processing were implemented successfully by selecting appropriate processing parameters based on the orthogonal experiment. |
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