Electrolytic machining gun barrel rifling cathode design method

Abstract

The invention relates to the technical field of gun barrel rifling cathode design, and discloses an electrolytic machining gun barrel rifling cathode design method which comprises the following steps: (1) shape reverse engineering; (2) selecting and analyzing materials; (3) surface treatment and coating technology; (4) precision manufacturing and quality control; (5) size and appearance detection; (6) installation and parameter optimization; and (7) processing test and iterative improvement. A design method for a gun barrel rifling cathode through electrolytic machining comprises the steps of reverse engineering of the shape, material selection and analysis, surface treatment and coating technology, precise manufacturing and quality control, size and appearance detection, installation and parameter optimization, machining testing and iterative improvement and the like. The problems existing in traditional electrolytic machining cathode design can be solved in a planned mode, and the machining quality and efficiency are improved.

Description

Technical Field

[0001] The invention relates to the technical field of gun barrel rifling cathode design, in particular to a method for designing a gun barrel rifling cathode through electrolytic machining. Background Art

[0002] Electrochemical Machining (ECM) is a non-traditional machining technology, mainly used for difficult-to-machine metal materials or workpieces with complex shapes. In the electrolytic machining process, the workpiece is used as the anode, the cathode is designed according to the required workpiece shape, and a voltage is applied between the workpiece and the cathode. The metal is removed by electrolysis to obtain the desired workpiece shape. Although electrolytic machining technology has been widely used in industry, there are still some problems with traditional methods, such as complex cathode design, difficult to control machining accuracy, and the need to further improve machining efficiency.

[0003] Traditional cathode design methods are mostly based on experience, which makes it difficult to accurately reflect the dynamic electrolyte flow and electric field distribution during processing, thus affecting the processing accuracy and efficiency. In addition, the selection of cathode materials and surface treatment processes have also become key factors in improving electrolytic processing performance. How to design a cathode with high precision, high efficiency and low cost has always been the goal pursued by the industry. Summary of the invention

[0004] The object of the present invention is to provide a cathode design method for electrolytic machining of gun barrel rifling to solve the problems raised in the above-mentioned background technology.

[0005] To achieve the above object, the present invention provides the following technical solution: a method for designing a cathode for electrolytic machining of a gun barrel rifling, comprising the following steps:

[0006] Step (1) Shape reverse engineering:

[0007] According to the specific shape and size requirements of the barrel inner diameter and rifling, the cathode geometry is determined by using 3D modeling software and reverse design principles to meet the electrolyte flow performance and efficiency of the electrolytic machining process;

[0008] Step (2) Material selection analysis:

[0009] Based on the comprehensive requirements of electrolytic machining, cathode materials with excellent conductivity and corrosion resistance are selected through material performance analysis to ensure the stability and economy of the cathode during electrolytic machining;

[0010] Step (3) Surface treatment and coating technology:

[0011] Surface treatment of the selected cathode material and application of coating technology to add conductive coating and anti-corrosion coating on the cathode surface to improve its durability and functionality;

[0012] Step (4) Precision manufacturing and quality control:

[0013] Use high-precision manufacturing technology to process cathodes according to design drawings to ensure that the processing size and appearance of each cathode meet the design requirements;

[0014] Step (5) Size and shape inspection:

[0015] After the cathode is manufactured, high-precision measuring equipment is used to accurately inspect the shape, size and surface quality, as well as the uniformity and adhesion strength of the coating to ensure that the cathode meets the precision requirements of electrolytic processing;

[0016] Step (6) Installation and parameter optimization:

[0017] Install the manufactured and inspected qualified cathode on the electrolytic processing equipment; optimize the processing parameters based on the experimental data, including adjusting the composition, concentration, temperature and flow rate of the electrolyte, as well as the operating voltage and frequency of the equipment;

[0018] Step (7) Processing test and iterative improvement:

[0019] The cathode is processed and tested in an actual production environment, processing data is collected and analyzed, and iterative improvements are made to the cathode based on feedback information to ensure that the processing efficiency and the processing quality of the barrel rifling meet industrial production standards.

[0020] Preferably, in step (1):

[0021] Cathode design: The gap is between 0.5mm and 1mm to allow the electrolyte to flow without causing excessive discharge;

[0022] The helix angle of the rifling is in the range of 15° to 30°;

[0023] The cathode advance speed was set within the travel speed range of 1 mm to 5 mm per minute.

[0024] Preferably, in step (2):

[0025] Conductivity requirements: To ensure the efficiency of electrolytic processing, the conductivity is set to be no less than the conductivity level of copper, that is, σ>=5.8×10^7S / m;

[0026] Corrosion resistance requirement: The cathode will work in the electrolyte for a long time, and the parameter is set to no more than 0.1mm / year;

[0027] Cathode material options: pure copper, copper-tungsten alloy or graphite.

[0028] Preferably, in step (3):

[0029] Surface treatment: Determine the surface roughness standard, the surface roughness level shall not exceed 0.4 microns;

[0030] Coating material selection: Nickel or nickel alloy coating is used to improve surface corrosion resistance and hardness; the coating thickness is controlled between 5 and 20 microns, uniform and free of bubbles and cracks.

[0031] Preferably, in step (4):

[0032] Manufacturing process options: including CNC milling, turning or EDM;

[0033] Manufacturing parameter settings: turning speed is 100-200m / min, and feed speed is set in the range of 0.01-0.05mm / rev.

[0034] Preferably, in step (5):

[0035] Shape and size inspection: For the critical dimensions of the cathode, the tolerance is set to ±0.01mm, and for non-critical dimensions, the tolerance is set to ±0.05mm.

[0036] Inspection contents: including but not limited to the length, diameter, pitch and depth of the cathode, ensuring that each indicator meets the design requirements;

[0037] Coating adhesion strength test: The adhesion strength of the coating is evaluated by tensile test, peel test or lateral impact test. The adhesion strength of the peel test is not less than 20N / mm.

[0038] Preferably, in step (6):

[0039] Install the cathode: adjust the relative position of the cathode and the workpiece to ensure that the initial spacing between them is between 0.1mm and 1mm;

[0040] Electrolyte parameter adjustment:

[0041] electrolyte composition, sodium nitrate or sodium hydroxide;

[0042] Concentration adjustment: set the initial value of electrolyte concentration between 50-200g / L;

[0043] Temperature control, the temperature range is set at 20℃ to 40℃ and needs to be maintained constant;

[0044] Flow rate setting, the flow rate setting value is 1-5L / min.

[0045] The beneficial effects are:

[0046] A design method for an electrolytic machining gun barrel rifling cathode includes shape reverse engineering, material selection analysis, surface treatment and coating technology, precision manufacturing and quality control, size and shape detection, installation and parameter optimization, and processing testing and iterative improvement. Through this method, problems existing in the design of traditional electrolytic machining cathodes can be solved in a planned manner, and processing quality and efficiency can be improved. The application of reverse engineering ensures that the cathode shape accurately matches the internal shape of the workpiece, and can also optimize the flow performance of the electrolyte. Through the precise control of parameter settings, it is ensured that the geometric size and surface quality of each cathode meet the design requirements, reducing rework and scrap rates. The detailed adjustment of electrolyte parameters allows precise control of the production process, thereby improving processing efficiency. The final processing test and iterative improvement steps ensure that the cathode design can quickly respond to changes in actual production and achieve continuous optimization. DETAILED DESCRIPTION

[0047] The following will be combined with the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0048] Embodiment, the invention provides a technical solution: a method for designing a cathode for electrolytic machining of a gun barrel rifling, comprising the following steps:

[0049] Step (1) Shape reverse engineering:

[0050] According to the specific shape and size requirements of the barrel inner diameter and rifling, the cathode geometry is determined by using 3D modeling software and reverse design principles to meet the electrolyte flow performance and efficiency of the electrolytic machining process;

[0051] Cathode design: The gap is between 0.5mm and 1mm to allow the electrolyte to flow without causing excessive discharge;

[0052] The helix angle of the rifling is in the range of 15° to 30°;

[0053] The cathode advance speed is set within a travel speed range of 1 mm to 5 mm per minute;

[0054] Step (2) Material selection analysis:

[0055] Based on the comprehensive requirements of electrolytic machining, cathode materials with excellent conductivity and corrosion resistance are selected through material performance analysis to ensure the stability and economy of the cathode during electrolytic machining;

[0056] Conductivity requirements: To ensure the efficiency of electrolytic processing, the conductivity is set to be no less than the conductivity level of copper, that is, σ>=5.8×10^7S / m;

[0057] Corrosion resistance requirement: The cathode will work in the electrolyte for a long time, and the parameter is set to no more than 0.1mm / year;

[0058] Cathode material selection: pure copper, copper-tungsten alloy or graphite;

[0059] Step (3) Surface treatment and coating technology:

[0060] Surface treatment of the selected cathode material and application of coating technology to add conductive coating and anti-corrosion coating on the cathode surface to improve its durability and functionality;

[0061] Surface treatment: Determine the surface roughness standard, the surface roughness level shall not exceed 0.4 microns;

[0062] Coating material selection: nickel or nickel alloy coating is used to improve surface corrosion resistance and hardness; the coating thickness is controlled at 5 to 20 microns, uniform and free of bubbles and cracks;

[0063] Step (4) Precision manufacturing and quality control:

[0064] Use high-precision manufacturing technology to process cathodes according to design drawings to ensure that the processing size and appearance of each cathode meet the design requirements;

[0065] Manufacturing process options: including CNC milling, turning or EDM;

[0066] Manufacturing parameter setting: turning speed is 100-200m / min, and feed speed is set in the range of 0.01-0.05mm / rev;

[0067] Step (5) Size and shape inspection:

[0068] After the cathode is manufactured, high-precision measuring equipment is used to accurately inspect the shape, size and surface quality, as well as the uniformity and adhesion strength of the coating to ensure that the cathode meets the precision requirements of electrolytic processing;

[0069] Shape and size inspection: For the critical dimensions of the cathode, the tolerance is set to ±0.01mm, and for non-critical dimensions, the tolerance is set to ±0.05mm.

[0070] Inspection contents: including but not limited to the length, diameter, pitch and depth of the cathode, ensuring that each indicator meets the design requirements;

[0071] Coating adhesion strength test: Evaluate the coating adhesion strength through tensile test, peel test or lateral impact test. The adhesion strength of the peel test shall not be less than 20N / mm.

[0072] Step (6) Installation and parameter optimization:

[0073] Install the manufactured and inspected qualified cathode on the electrolytic processing equipment; optimize the processing parameters based on the experimental data, including adjusting the composition, concentration, temperature and flow rate of the electrolyte, as well as the operating voltage and frequency of the equipment;

[0074] Install the cathode: adjust the relative position of the cathode and the workpiece to ensure that the initial spacing between them is between 0.1mm and 1mm;

[0075] Electrolyte parameter adjustment:

[0076] electrolyte composition, sodium nitrate or sodium hydroxide;

[0077] Concentration adjustment: set the initial value of electrolyte concentration between 50-200g / L;

[0078] Temperature control, the temperature range is set at 20℃ to 40℃ and needs to be maintained constant;

[0079] Flow rate setting, the setting value of flow rate is 1-5L / min;

[0080] Step (7) Processing test and iterative improvement:

[0081] The cathode is processed and tested in an actual production environment, processing data is collected and analyzed, and iterative improvements are made to the cathode based on feedback information to ensure that the processing efficiency and the processing quality of the barrel rifling meet industrial production standards.

[0082] Embodiment 1:

[0083] Electrochemical machining parameters:

[0084] Cathode material: pure copper;

[0085] Cathode dimensions: inner diameter 100mm, rifling helix angle 20°;

[0086] Gap between cathode and workpiece: 0.8mm;

[0087] Cathode advance speed: 3mm / min;

[0088] Electrolyte composition: sodium hydroxide solution;

[0089] Electrolyte concentration: 150g / L;

[0090] Electrolyte temperature: 30°C;

[0091] Electrolyte flow rate: 2L / min;

[0092] Working voltage: 10V;

[0093] Operating frequency: 1kHz.

[0094] Experimental data and improvements:

[0095] The average tolerance of the rifling width was measured to be ±0.008 mm;

[0096] The average tolerance of rifling depth is ±0.009mm;

[0097] Surface roughness Ra is 1.2μm;

[0098] The coating adhesion strength is 25N / mm.

[0099] Improvement measures:

[0100] Due to slight variations in rifling depth, the electrolysis effect was increased by increasing the temperature and flow rate of the electrolyte. After improvement, the temperature was increased to 35°C and the flow rate was increased to 3L / min.

[0101] Embodiment 2:

[0102] Electrochemical machining parameters:

[0103] Cathode material: copper-tungsten alloy;

[0104] Cathode dimensions: inner diameter 150mm, rifling helix angle 15°;

[0105] Gap between cathode and workpiece: 0.5mm;

[0106] Cathode advance speed: 1mm / min;

[0107] Electrolyte composition: sodium nitrate solution;

[0108] Electrolyte concentration: 100g / L;

[0109] Electrolyte temperature: 25°C;

[0110] Electrolyte flow rate: 4L / min;

[0111] Working voltage: 12V;

[0112] Working frequency: 500Hz;

[0113] Experimental data and improvements:

[0114] The average tolerance of the rifling width was measured to be ±0.007 mm;

[0115] The average tolerance of rifling depth is ±0.007mm;

[0116] Surface roughness Ra is 0.9μm;

[0117] The coating adhesion strength is 28N / mm.

[0118] Improvement measures:

[0119] In order to further reduce the surface roughness, the coating process was optimized, the micro defects in the nickel alloy coating were reduced, and the coating thickness was adjusted to 10 microns.

[0120] Embodiment three:

[0121] Electrochemical machining parameters:

[0122] Cathode material: graphite;

[0123] Cathode dimensions: inner diameter 80mm, rifling helix angle 30°;

[0124] Gap between cathode and workpiece: 1mm;

[0125] Cathode advance speed: 5mm / min;

[0126] Electrolyte composition: sodium hydroxide solution;

[0127] Electrolyte concentration: 200g / L;

[0128] Electrolyte temperature: 40°C;

[0129] Electrolyte flow rate: 1L / min;

[0130] Working voltage: 8V;

[0131] Operating frequency: 1.5kHz.

[0132] Experimental data and improvements:

[0133] The average tolerance of the rifling width was measured to be ±0.011 mm;

[0134] The average tolerance of rifling depth is ±0.010mm;

[0135] Surface roughness Ra is 1.6μm;

[0136] The coating adhesion strength is 22N / mm.

[0137] Improvement measures:

[0138] Because the rifling size fluctuates greatly, the cathode design is adjusted to optimize its shape, and the electrolyte flow rate is increased to 2L / min to improve the processing quality. In addition, the cathode forward speed is reduced to 4mm / min to reduce processing defects.

[0139] Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and spirit of the present invention, and that the scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A method for designing a cathode for electrolytic machining of a gun barrel rifling, characterized in that: The following steps are involved: Step (1) Shape reverse engineering: According to the specific shape and size requirements of the barrel inner diameter and rifling, the cathode geometry is determined by using 3D modeling software and reverse design principles to meet the electrolyte flow performance and efficiency of the electrolytic machining process; Step (2) Material selection analysis: Based on the comprehensive requirements of electrolytic machining, cathode materials with excellent conductivity and corrosion resistance are selected through material performance analysis to ensure the stability and economy of the cathode during electrolytic machining; Step (3) Surface treatment and coating technology: Surface treatment of the selected cathode material and application of coating technology to add conductive coating and anti-corrosion coating on the cathode surface to improve its durability and functionality; Step (4) Precision manufacturing and quality control: Use high-precision manufacturing technology to process cathodes according to design drawings to ensure that the processing size and appearance of each cathode meet the design requirements; Step (5) Size and shape inspection: After the cathode is manufactured, high-precision measuring equipment is used to accurately inspect the shape, size and surface quality, as well as the uniformity and adhesion strength of the coating to ensure that the cathode meets the precision requirements of electrolytic processing; Step (6) Installation and parameter optimization: Install the manufactured and inspected qualified cathode on the electrolytic processing equipment; optimize the processing parameters based on the experimental data, including adjusting the composition, concentration, temperature and flow rate of the electrolyte, as well as the operating voltage and frequency of the equipment; Step (7) Processing test and iterative improvement: The cathode is processed and tested in an actual production environment, processing data is collected and analyzed, and iterative improvements are made to the cathode based on feedback information to ensure that the processing efficiency and the processing quality of the barrel rifling meet industrial production standards.

2. A cathode design method for electrolytic machining of gun barrel rifling according to claim 1, characterized in that: In step (1): Cathode design: The gap is between 0.5mm and 1mm to allow the electrolyte to flow without causing excessive discharge; The helix angle of the rifling is in the range of 15° to 30°; The cathode advance speed was set within the travel speed range of 1 mm to 5 mm per minute.

3. A cathode design method for electrolytic machining of gun barrel rifling according to claim 2, characterized in that: In step (2): Conductivity requirements: To ensure the efficiency of electrolytic processing, the conductivity is set to be no less than the conductivity level of copper, that is, σ>=5.8×10^7S / m; Corrosion resistance requirement: The cathode will work in the electrolyte for a long time, and the parameter is set to no more than 0.1mm / year; Cathode material options: pure copper, copper-tungsten alloy or graphite.

4. A method for designing a cathode for electrolytic machining of a gun barrel rifling according to claim 3, characterized in that: In step (3): Surface treatment: Determine the surface roughness standard, the surface roughness level shall not exceed 0.4 microns; Coating material selection: Nickel or nickel alloy coating is used to improve surface corrosion resistance and hardness; the coating thickness is controlled between 5 and 20 microns, uniform and free of bubbles and cracks.

5. A cathode design method for electrolytic machining of gun barrel rifling according to claim 4, characterized in that: In step (4): Manufacturing process options: including CNC milling, turning or EDM; Manufacturing parameter settings: turning speed is 100-200m / min, and feed speed is set in the range of 0.01-0.05mm / rev.

6. A cathode design method for electrolytic machining of gun barrel rifling according to claim 5, characterized in that: In step (5): Shape and size inspection: For the critical dimensions of the cathode, the tolerance is set to ±0.01mm, and for non-critical dimensions, the tolerance is set to ±0.05mm. Inspection contents: including but not limited to the length, diameter, pitch and depth of the cathode, ensuring that each indicator meets the design requirements; Coating adhesion strength test: The adhesion strength of the coating is evaluated by tensile test, peel test or lateral impact test. The adhesion strength of the peel test is not less than 20N / mm.

7. A cathode design method for electrolytic machining of gun barrel rifling according to claim 6, characterized in that: In step (6): Install the cathode: adjust the relative position of the cathode and the workpiece to ensure that the initial spacing between them is between 0.1mm and 1mm; Electrolyte parameter adjustment: electrolyte composition, sodium nitrate or sodium hydroxide; Concentration adjustment, set the initial value of electrolyte concentration between 50-200g / L; Temperature control, the temperature range is set at 20℃ to 40℃ and needs to be maintained constant; Flow rate setting, the flow rate setting value is 1-5L / min.