Analysis of electrochemical machining of involute internal spline by foamed metal cathode.

Foamed metal materials are introduced as a novel tool to manufacture cathodes for the electrochemical machining (ECM) of involute internal spline made from difficult-to-cut materials. This paper analyzes the porosity density and electrolyte flow characteristics of foamed metal cathodes. The geometric and mathematical model of the involute internal spline by ECM is built, and electric field simulations are conducted by using the COMSOL Multiphysics software to determine the ECM results. Based on the simulation results, suitable initial process parameters are obtained and relative process experiments are carried out. The experiment results demonstrate that foamed metal material can be used to fabricate tool cathodes for ECM of involute internal spline. When the machining voltage is 10 V, the electrolyte type is 2% NaCl + 8% NaNO3 solution, and cathodic feed rate is 1.00 mm/min, the involute internal spline machined by axial ECM can achieve better profiles that meet the finishing accuracy and precision requirements. The experimental application of foamed metal cathode lays a new technical foundation for ECM to manufacture complex internal structures and from design theory to contemporary industrial praxis. [ABSTRACT FROM AUTHOR]