Modularized cathode device capable of avoiding secondary electrolysis of electrolytic milling and grinding machining surface

Abstract

The invention discloses a modular cathode device capable of avoiding secondary electrolysis of an electrolytic milling and grinding machining surface. The modular cathode device comprises an electrolyte conduction unit and an electrical conduction and control unit. The electrolyte conduction unit is composed of an insulating base body, a liquid supply template and a liquid outlet hole, and a uniform electrolyte supply path is formed. The electric conduction and control unit achieves independent electric conduction control over the electric conduction grinding wheel block through the electric conduction block and the carbon brush. The device adopts a modular design, supports quick disassembly and assembly and local module replacement, and reduces the use cost. In the machining process, the carbon brush is in sliding contact with the rotating electricity leading block, only the multiple conductive grinding wheel blocks at the front end are powered on for electrolytic milling and grinding, the other grinding wheel blocks are powered off for pure mechanical milling and grinding, the secondary electrolysis problem is effectively avoided, and the quality of the machined surface is improved. Meanwhile, by adjusting parameters such as electrolyte flow and voltage, the machining effect can be optimized, and different machining requirements can be met.

Description

Technical Field

[0001] The present invention relates to the technical field of electrochemical machining, and particularly to a modular cathode device capable of avoiding secondary electrolysis on the surface of electrochemical milling and grinding. Background Art

[0002] With the rapid development of the aviation industry, integral structural components are increasingly widely used in new aircraft, such as key components like integral casings, integral blisks, integral frame structures, integral panels, and girders. These components are usually made of difficult-to-machine materials such as titanium alloys, nickel-based superalloys, and metal matrix composites, and have characteristics such as large size, complex structure, and thin walls, with a large amount of material removal during the machining process. When traditional machining methods cut these materials, they face problems such as large cutting forces, high cutting temperatures, and rapid tool wear, and are prone to residual stress and deformation after machining, affecting the accuracy and performance of parts. Even when using thermal machining technologies such as electrical discharge machining, although there is no cutting force, a recast layer will be formed on the machined surface, which has an adverse effect on the mechanical properties and fatigue life of the material. Therefore, the innovation and breakthrough of manufacturing technology are still the core driving forces for the development of the aviation industry. Only by continuously overcoming the bottlenecks of manufacturing technology can the urgent needs of the aviation field for high-precision and high-performance parts be met.

[0003] Electrochemical machining technology shows great potential in the field of difficult-to-machine materials due to its advantages such as no residual stress, no tool wear, and no recast layer. Electrochemical milling technology combines electrochemical machining with numerical control technology and uses a hollow tubular electrode to machine according to a preset trajectory, capable of efficiently removing materials and machining complex feature parts. However, the accuracy of electrochemical machining is relatively low, and overcutting is prone to occur, restricting its application in precision machining.

[0004] Electrochemical milling and grinding technology further develops on this basis, using a conductive cathode coated with abrasive grains as a tool, combining the composite machining principle of electrochemical dissolution and mechanical grinding, and having both the high efficiency of electrochemical machining and the high surface quality of grinding. However, the existing electrochemical milling and grinding technology has a significant secondary electrolysis problem: the machined surface will be electrolyzed again during subsequent machining. Due to the increase in the machining gap and the decrease in current density, fine corrosion pits are easily formed on the workpiece surface, resulting in a decline in surface quality. This problem severely restricts the application of electrochemical milling and grinding technology in the field of high-precision machining. Therefore, developing an electrochemical milling and grinding device that can effectively avoid secondary electrolysis is of great significance for improving the machined surface quality and meeting the stringent requirements of the aviation industry. Summary of the Invention

[0005] The purpose of this section is to outline some aspects of the embodiments of the present invention and briefly introduce some preferred embodiments. Some simplifications or omissions may be made in this section, as well as in the abstract and title of the present application, to avoid obscuring the purpose of this section, the abstract, and the title. However, such simplifications or omissions shall not be used to limit the scope of the present invention.

[0006] Therefore, to solve the above technical problems, the present invention provides the following technical solution: a modular cathode device capable of avoiding secondary electrolysis on the surface of electrolytic milling and grinding, comprising an electrolyte conduction unit and an electrical conduction and control unit;

[0007] The electrolyte conduction unit includes an insulating substrate, which is in a hollow columnar structure. The inner cavity of the insulating substrate forms an electrolyte channel; a plurality of liquid supply templates are arranged in a circular array at the bottom of the insulating substrate, and liquid outlet holes communicating with the electrolyte channel are formed on the liquid supply templates. An electrolyte supply path is formed through the electrolyte channel and the liquid outlet holes. The liquid outlet holes are used to spray the electrolyte onto the machining area, and a workpiece is arranged in the machining area; the insulating substrate includes a rod portion and a head portion. A plurality of sliding grooves are axially formed on the side wall of the rod portion, and a plurality of tenon grooves are circumferentially formed on the head portion.

[0008] The electrical conduction and control unit includes a current-carrying block and a carbon brush. The current-carrying block is slidably clamped in the sliding groove of the rod portion and is fixed by an insulating sleeve cover; a conductive grinding wheel block is inserted into the tenon groove of the head portion, and each conductive grinding wheel block realizes independent conductive control through the corresponding current-carrying block; the carbon brush is arranged on one side of the current-carrying block. The carbon brush is located at the front end of the feeding direction of the cathode device and forms a sliding electrical contact with the side wall of the current-carrying block in a rotating state.

[0009] As a preferred solution of the modular cathode device capable of avoiding secondary electrolysis on the surface of electrolytic milling and grinding according to the present invention, wherein: the sliding grooves are arranged in a circular array on the circumferential outer side wall of the rod portion, the tenon grooves are arranged in a circular array on the circumferential outer side wall of the head portion, and the number of sliding grooves is the same as that of the tenon grooves.

[0010] As a preferred solution of the modular cathode device capable of avoiding secondary electrolysis on the surface of electrolytic milling and grinding according to the present invention, wherein: the insulating substrate and the insulating sleeve cover are made of polyether ether ketone material.

[0011] As a preferred solution of the modular cathode device capable of avoiding secondary electrolysis on the surface of electrolytic milling and grinding according to the present invention, wherein: the conductive grinding wheel block is a metal-based diamond grinding wheel, a metal-based CBN grinding wheel, a electroplated diamond metal block, or an electroplated CBN abrasive metal block.

[0012] As a preferred embodiment of the modular cathode device capable of avoiding secondary electrolysis on the surface during electro-chemical milling, during the rotation of the cathode, through the sliding contact between the carbon brush and the current-conducting block, only 1-3 current-conducting grinding wheel blocks located at the front end in the feeding direction are energized for electro-chemical milling, and the remaining current-conducting grinding wheel blocks perform pure mechanical milling in a de-energized state.

[0013] As a preferred embodiment of the modular cathode device capable of avoiding secondary electrolysis on the surface during electro-chemical milling, the insulating sleeve cover is fixed to the insulating base body by the first screw group and presses downward on the current-conducting block; the current-conducting grinding wheel block is connected to the lower end of the current-conducting block by the second screw group.

[0014] Advantages of the present invention:

[0015] 1. The present invention adopts a modular design. The insulating base body, the current-conducting block and the current-conducting grinding wheel block are quickly disassembled and assembled through sliding grooves, tenon grooves and screw groups, significantly improving the maintainability and operability of the device; local modules (such as current-conducting grinding wheel blocks) can be independently replaced, avoiding the problem of overall scrapping caused by local damage of the traditional integral cathode, and reducing the use cost of the tool cathode; the modular design also supports flexible adjustment of the number and arrangement mode of current-conducting grinding wheel blocks according to processing requirements, improving the applicability and economy of the device.

[0016] 2. Through the sliding contact conduction mechanism between the carbon brush and the current-conducting block, the present invention only energizes multiple current-conducting grinding wheel blocks located at the front end in the feeding direction for electro-chemical milling, and the remaining current-conducting grinding wheel blocks perform pure mechanical milling in a de-energized state; this design effectively avoids the problem of surface quality degradation caused by secondary electrolysis of the machined surface in the traditional cathode device, and significantly improves the uniformity and consistency of the machined surface.

[0017] 3. The present invention can precisely control the ratio of electro-chemical machining to mechanical milling by adjusting the number, arrangement mode of current-conducting grinding wheel blocks and the applied voltage, meeting the requirements of different materials and different machining precisions; it supports multi-mode machining, including pure electro-chemical machining, pure mechanical milling and composite machining modes, significantly improving the process adaptability and machining efficiency of the device.

[0018] 4. Through the hollow structure design of the insulating base body, the present invention optimizes the electrolyte flow path, and realizes the uniform spraying of the electrolyte through the liquid outlet holes, ensuring sufficient cooling of the machining area and timely discharge of electrolysis products; this design effectively avoids the problem of unstable machining quality caused by uneven electrolyte supply in the traditional cathode device. Description of the Drawings

[0019] To more clearly illustrate the technical solutions of the embodiments of the present invention, the following will briefly introduce the drawings required for the description of the embodiments. Obviously, the drawings in the following description are only some embodiments of the present invention. For those of ordinary skill in the art, without creative efforts, other drawings can also be obtained based on these drawings. Among them:

[0020] Figure 1 It is a schematic diagram of the overall structure of the present invention.

[0021] Figure 2 It is an exploded structure schematic diagram of the structure of the present invention.

[0022] Figure 3 It is a schematic diagram of the overall structure of the processing system for electrolytic milling of the present invention.

[0023] Figure 4 It is a schematic diagram of the cathode power supply structure during electrolytic milling of the present invention.

[0024] In the figure: 100, electrolyte conduction unit; 101, insulating substrate; 1011, rod part; 1012, head part; 102, liquid supply template; 103, liquid outlet hole; 104, first screw group;

[0025] 200, electrical conduction and control unit; 201, power supply block; 202, carbon brush; 203, insulating sleeve cover; 204, conductive grinding wheel block; 205, second screw group. Specific embodiments

[0026] To make the above objects, features, and advantages of the present invention more obvious and understandable, the following will make a detailed description of the specific embodiments of the present invention in conjunction with the drawings of the specification.

[0027] In the following description, many specific details are set forth to fully understand the present invention. However, the present invention can also be implemented in other ways different from those described herein. Those skilled in the art can make similar extensions without departing from the connotation of the present invention. Therefore, the present invention is not limited by the specific embodiments disclosed below.

[0028] Secondly, the so-called "one embodiment" or "embodiment" herein refers to a specific feature, structure, or characteristic that can be included in at least one implementation of the present invention. The "in one embodiment" that appears in different places in this specification does not necessarily refer to the same embodiment, nor is it a separate or selectively exclusive embodiment from other embodiments.

[0029] Next, the present invention will be described in detail with reference to the schematic diagrams. When describing the embodiments of the present invention in detail, for the convenience of explanation, the cross-sectional views showing the device structure will be locally enlarged out of the general scale, and the schematic diagrams are only examples and should not limit the scope of protection of the present invention herein. In addition, in actual production, three-dimensional spatial dimensions including length, width, and depth should be included.

[0030] Referring to Figures 1 to 4 , an embodiment of the present invention provides a modular cathode device that can avoid secondary electrolysis on the surface of electrolytic milling, including an electrolyte conduction unit 100 and an electrical conduction and control unit 200;

[0031] The electrolyte conduction unit 100 includes an insulating substrate 101. The insulating substrate 101 has a hollow columnar structure, and its inner cavity forms an electrolyte channel. The insulating substrate 101 includes a rod portion 1011 and a head portion 1012. A plurality of sliding grooves are axially formed on the side wall of the rod portion 1011, and these sliding grooves are arranged in a circular array on the circumferential outer wall of the rod portion 1011. A plurality of tenon grooves are circumferentially formed on the head portion 1012, and these tenon grooves are arranged in a circular array on the circumferential outer wall of the head portion 1012, and the number of sliding grooves is the same as that of the tenon grooves. Both the insulating substrate 101 and the insulating sleeve cover 203 are made of polyether ether ketone material. A plurality of liquid supply templates 102 are arranged in a circular array at the bottom of the insulating substrate 101. Liquid outlet holes 103 communicating with the electrolyte channel are formed on the liquid supply templates 102. An electrolyte supply path is formed through the electrolyte channel and the liquid outlet holes 103. The liquid outlet holes 103 are used to spray the electrolyte onto the machining area, and a workpiece is arranged in the machining area;

[0032] The electrical conduction and control unit 200 includes a current-carrying block 201 and a carbon brush 202. The current-carrying block 201 is slidably clamped in the sliding groove of the rod portion 1011, and is fixed to the insulating substrate 101 through the insulating sleeve cover 203 and the first screw group 104, and is pressed downward on the current-carrying block 201. A conductive grinding wheel block 204 is inserted into the tenon groove of the head portion 1012. The conductive grinding wheel block 204 is a metal-based diamond grinding wheel, a metal-based CBN grinding wheel, an electroplated diamond metal block, or an electroplated CBN abrasive metal block. Each conductive grinding wheel block 204 realizes independent conductive control through the corresponding current-carrying block 201, and is connected to the lower end of the current-carrying block 201 through the second screw group 205. The carbon brush 202 is arranged on one side of the current-carrying block 201 and is located at the front end in the feeding direction of the cathode device. The carbon brush 202 forms a sliding electrical contact with the side wall of the rotating current-carrying block 201. During the rotation of the cathode, through the sliding contact between the carbon brush 202 and the current-carrying block 201, only 1-3 conductive grinding wheel blocks 204 located at the front end in the feeding direction are energized for electrolytic milling, and the remaining conductive grinding wheel blocks 204 perform pure mechanical milling in the power-off state.

[0033] In this embodiment:

[0034] As Figure 1 , 2 shown, during installation, the electricity-conducting block 201 is snapped into the chute of the rod portion 1011 of the insulating base body 101, and is pressed downward and fixed on the insulating base body 101 through the insulating sleeve cover 203 and the first screw group 104. At the same time, the conductive grinding wheel block 204 is inserted upward into the mortise groove of the head portion 1012 of the insulating base body 101, and is fixed to the lower end of each corresponding electricity-conducting block 201 through the second screw group 205, so that the conductive grinding wheel block 204 not only realizes electrical connection with the electricity-conducting block 201, but also is mechanically fixed on the insulating base body 101.

[0035] As Figure 3 shown, during machining, the cathode device is connected to the negative pole of the power supply, and the workpiece is connected to the positive pole of the power supply. The cathode device rotates and moves forward along the feeding direction to remove the material of the workpiece. The carbon brush 202 is arranged at the front end of the cathode device in the feeding direction, and forms a sliding electrical contact with the side wall of the electricity-conducting block 201 in the rotating state. Since the circumferential coverage range of the carbon brush 202 is limited, it will only form an electrical connection with the electricity-conducting block 201 when the electricity-conducting block 201 rotates below the carbon brush 202, so that the corresponding conductive grinding wheel block 204 is powered on.

[0036] As Figure 4 shown, during the cathode rotation machining process, only the electricity-conducting block 201 that rotates to the machining area in front of the cathode is always conductive, that is, only several (preferably 1-3) conductive grinding wheel blocks 204 in front of the feeding direction perform electrolytic milling machining; these conductive grinding wheel blocks 204 perform electrolysis and mechanical milling machining simultaneously in the powered-on state; while the other conductive grinding wheel blocks 204 at the back are in a powered-off state because they do not form an electrical connection with the carbon brush 202, and only perform pure mechanical milling machining; such a design ensures that the surface that has been electrolytically machined will not be subjected to secondary electrolysis by the conductive grinding wheel blocks 204 at the back, thereby further improving the surface quality and machining accuracy of the electrolytic milling machining.

[0037] During machining, the electrolyte is evenly sprayed onto the machining area through the internal channel and the liquid outlet hole 103 of the insulating base body 101 to ensure the full progress of the electrolytic reaction and the timely cooling of the machining area.

[0038] In this embodiment, by adjusting parameters such as the electrolyte flow rate, voltage, and feeding speed, the machining effect can be further optimized to meet the requirements of different materials and machining accuracies.

[0039] It should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and not to limit them. Although the present invention has been described in detail with reference to the preferred embodiments, those of ordinary skill in the art should understand that the technical solutions of the present invention can be modified or equivalently replaced without departing from the spirit and scope of the technical solutions of the present invention, and they should all be covered within the scope of the claims of the present invention.

Claims

1. A modular cathode device capable of avoiding secondary electrolysis of electrolytic milling surface, characterized in that: It comprises an electrolyte conduction unit (100) and an electrical conduction and control unit (200); The electrolyte conducting unit (100) comprises an insulating substrate (101), the insulating substrate (101) is in a hollow columnar structure, and the inner cavity of the insulating substrate (101) forms an electrolyte channel; a plurality of liquid supply templates (102) are arranged in a circular array at the bottom of the insulating substrate (101), and a liquid outlet hole (103) connected to the electrolyte channel is opened on the liquid supply template (102), and an electrolyte supply path is formed by the electrolyte channel and the liquid outlet hole (103), and the liquid outlet hole (103) is used to spray the electrolyte to a processing area, and a workpiece is arranged in the processing area; the insulating substrate (101) comprises a rod portion (1011) and a head portion (1012), and a plurality of slide grooves are opened axially on the side wall of the rod portion (1011), and a plurality of tongue and grooves are opened circumferentially on the head portion (1012); The electrical conduction and control unit (200) comprises an electric conduction block (201) and a carbon brush (202); the electric conduction block (201) is slidably engaged in a slide groove of the rod portion (1011) and fixed by an insulating cover (203); a conductive grinding wheel block (204) is inserted into the mortise and tenon groove of the head portion (1012); each conductive grinding wheel block (204) realizes independent conduction control through the corresponding electric conduction block (201); the carbon brush (202) is arranged on one side of the electric conduction block (201), the carbon brush (202) is located at the front end in the feeding direction of the cathode device, and the carbon brush (202) forms a sliding electrical contact with the side wall of the electric conduction block (201) in a rotating state.

2. The modular cathode device capable of avoiding secondary electrolysis of electrolytic milling surface as claimed in claim 1, characterized in that: The slide groove annular array is arranged on the circumferential outer wall of the rod portion (1011), and the tongue groove annular array is arranged on the circumferential outer wall of the head portion (1012), and the number of the slide grooves is consistent with the number of the tongue grooves.

3. The modular cathode device capable of avoiding secondary electrolysis of electrolytic milling surface as claimed in claim 1, characterized in that: The insulating base (101) and the insulating sleeve cover (203) are made of polyetheretherketone material.

4. The modular cathode device capable of avoiding secondary electrolysis of electrolytic milling surface as claimed in claim 1, characterized in that: The conductive grinding wheel block (204) is a metal-based diamond grinding wheel, a metal-based CBN grinding wheel, an electroplated diamond metal block or an electroplated CBN abrasive metal block.

5. The modular cathode device capable of avoiding secondary electrolysis of electrolytic milling surface as claimed in claim 1, characterized in that: During the cathode rotation process, through the sliding contact between the carbon brush (202) and the lead block (201), only the conductive grinding wheel block (204) located at the front end of the feeding direction is energized for electrolytic milling processing, and the remaining conductive grinding wheel blocks (204) are powered off to perform pure mechanical milling processing.

6. The modular cathode device capable of avoiding secondary electrolysis of electrolytic milling surface as claimed in claim 1, characterized in that: The insulating sleeve cover (203) is fixed to the insulating base (101) by a first screw group (104) and pressed downwardly onto the lead block (201); the conductive grinding wheel block (204) is connected to the lower end of the lead block (201) by a second screw group (205).

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