Electrolytic machining device for array boss of integral plate and machining method of electrochemical machining device

Abstract

The invention relates to an electrochemical machining device for an array boss of an integral plate and a machining method of the electrochemical machining device. The electrolytic machining device comprises a rack, an electrolytic bath, a workpiece platform and a cathode. The cathode is of a double-layer tubular body structure and comprises an inner cavity and an outer cavity which are isolated from each other, the inner cavity and the outer cavity are communicated with the electrolyte supply tank through pipelines respectively, and electrolyte outlet holes corresponding to the inner cavity and the outer cavity respectively are formed in the bottom of the cathode. The electrolyte enters the inner cavity and the outer cavity and then flows out from the corresponding electrolyte outlet holes; an insulating layer is arranged on the inner wall of the electrolyte outlet hole, and a chamfer is machined at the bottom of the electrolyte outlet hole. The array boss of the whole plate is machined through a cathode forming method, the corrosion effect of current on the side wall of the boss is avoided through the electrolyte outlet holes arranged in an array mode, the insulating layers and the chamfering structures of the electrolyte outlets and the double-cavity structure of the cathode, and high-precision machining of the micro array boss small in taper and large in height can be achieved.

Description

Technical Field

[0001] This invention relates to the field of electrolytic machining, and more specifically to an electrolytic machining apparatus and method for an array of bosses on an integral plate. Background Technology

[0002] Electrolytic machining is a non-contact special machining technology that removes materials through the principle of electrochemical corrosion of metal anodic electrodes. During electrolytic machining, both the cathode and anode are simultaneously immersed in an electrolyte of suitable composition and concentration. The material to be processed is connected to the positive terminal of the power supply, while the forming tool is connected to the negative terminal. By controlling appropriate machining parameters, the material can be removed from the workpiece as needed. Due to its characteristics, electrolytic machining offers advantages such as being unrestricted by the mechanical properties of the material being processed, high processing efficiency, good surface quality, no wear on the tool electrodes, and the absence of macroscopic mechanical cutting forces. After machining, the workpiece has no residual stress, no burrs or flash, and low surface roughness.

[0003] Fabricating high-precision micro-array boss structures on metal sheet surfaces is a key component in the manufacturing of precision connectors, high-efficiency heat dissipation devices, and other products. Currently, there are two main electrolytic machining methods for bosses: First, machining individual bosses on the casing. This method is typically suitable for single large bosses and is difficult to achieve efficient forming of micro-array bosses on an integral sheet. Second, mask electrolytic machining. This method uses a fixed cathode and anode structure, which, while applicable to array microstructures, causes current to dissipate from the cathode during the machining of micro-bodies, reaching the workpiece sidewalls through the electrolyte. This can lead to unintended electrolytic erosion on the boss sides, resulting in excessive boss taper. Furthermore, while this method is suitable for bosses below 0.5mm, lateral corrosion intensifies when the boss height exceeds 0.5mm, making it even more difficult to maintain the boss taper and significantly increasing the machining difficulty. Therefore, developing an electrolytic machining device suitable for array bosses on integral sheets has become a critical problem urgently needing to be solved in this technical field. Summary of the Invention

[0004] The purpose of this invention is to overcome the above-mentioned drawbacks and provide an electrolytic machining apparatus for an array of bosses on an integral plate. This apparatus can effectively solve the problem of corrosion of the boss side by the electrolyte and effectively control the taper size of the array bosses.

[0005] To achieve the above objectives, the present invention adopts the following technical solution: It includes a frame, on which an electrolytic cell is mounted. The electrolytic cell contains a workpiece platform for fixing the workpiece to be processed. A vertically arranged cathode is suspended above the workpiece platform. The cathode has a double-layered tubular structure, including an inner cavity and an outer cavity that are isolated from each other. The inner and outer cavities are respectively connected to an electrolyte supply tank via pipelines. The bottom of the cathode has electrolyte outlet holes corresponding to the inner and outer cavities, respectively. Electrolyte enters the inner cavity... The electrolyte flows out through the corresponding electrolyte outlet holes after passing through the inner and outer cavities. An insulating layer is provided on the inner wall of each electrolyte outlet hole, and a chamfer is machined at the bottom of the outlet hole. The workpiece platform is connected to the positive terminal of the power supply via a first wire, and the cathode is connected to the negative terminal of the power supply via a second wire. A processing gap is provided between the cathode and the workpiece to be processed to allow electrolyte flow. The electrolytic cell is connected to a waste electrolyte tank via a pipeline. The horizontal position of the electrolytic cell on the frame is adjustable, and the height of the cathode from the workpiece platform is adjustable.

[0006] The cathode has a stepped structure, including an inner tube and an outer tube arranged concentrically. The outer tube is shorter than the inner tube. The top of the inner tube is provided with an upper end cap that is sealed to it. The bottom of the inner tube is open and fixed to the lower end cap of the outer tube. A flange is provided on the outer wall of the inner tube. The top of the outer tube is open and bolted to the flange. The bottom of the outer tube is provided with a lower end cap integrally formed therewith. The top of the lower end cap has a groove that forms an insertion fit with the bottom of the inner tube. The bottom of the lower end cap extends out of the outer tube. The electrolyte outlet holes are provided through the lower end cap and are arranged in a radial array from the center of the lower end cap. An inner cavity is formed between the inner tube, the upper end cap, and the lower end cap. An outer cavity is formed between the outer tube, the flange, the lower end cap, and the inner tube nested with the outer tube.

[0007] The inner tube is symmetrically provided with two inner cavity liquid inlets, and the two inner cavity liquid inlets are connected by a first pipeline. The first pipeline is connected to the electrolyte supply tank in sequence through the inner cavity liquid inlet pipe and the water pump. The outer tube is symmetrically provided with two external cavity liquid inlets, which are connected by a second pipeline. The second pipeline is connected to the external cavity liquid inlet pipe, which is connected to a pulse pump. A pressure gauge is also connected to the external cavity liquid inlet pipe. A third pipeline, which is connected to the electrolyte supply tank, is bypassed by the external cavity liquid inlet pipe. A solenoid valve is connected to the third pipeline.

[0008] The inner cavity is equipped with a stirring device, which includes a spiral shaft that passes through the upper end cover. The spiral shaft is connected to a servo motor via a coupling, and spiral blades are fixed on the spiral shaft located in the inner cavity. The upper end cover has a through hole for the spiral shaft to pass through, and a ring is embedded in the through hole. The inner wall of the ring is provided with a lubricating layer. The servo motor is fixed to the upper end cover by a motor bracket.

[0009] The bottom of the cathode is also provided with a tool setting device that can be detachably fixed thereto. The tool setting device includes a sleeve and a probe set at the center of the bottom of the sleeve. The sleeve is fitted onto the lower end cover and is a hollow cylindrical body with an open top. The probe includes a first cylinder, a second cylinder and a cone arranged sequentially from top to bottom. The first baffle is provided with a positioning hole that matches the apex of the cone.

[0010] The workpiece platform is connected to the electrolytic cell via a column. The two ends of the workpiece platform are respectively provided with a first baffle and a second baffle. The first baffle and the second baffle are integrally formed with the workpiece platform. One end of the workpiece to be processed is positioned against the first baffle, and the other end of the workpiece to be processed is provided with a pair of wedge blocks that cooperate with the second baffle. The workpiece to be processed is clamped on the workpiece platform by adjusting the position of the wedge blocks.

[0011] The electrolytic cell is adjusted horizontally via X-axis and Y-axis moving components, and the cathode is adjusted vertically via Z-axis moving components. The X-axis, Y-axis, and Z-axis moving components are all combinations of ball screw pairs and linear guide pairs, and the Y-axis and Z-axis moving components are fixed on the frame.

[0012] The cathode, first pipeline, second pipeline, third pipeline, inner cavity liquid inlet pipe, outer cavity liquid inlet pipe, and pressure gauge are all fixed to the connecting beam by clamp-type fixtures.

[0013] Another object of the present invention is to provide a processing method for an electrolytic machining apparatus for an array of bosses on an integral sheet metal part, comprising the following steps: S1: After cleaning the workpiece, place it on the workpiece platform and clamp it on the workpiece platform with wedge blocks. Connect the first wire and the second wire to the positive and negative terminals of the power supply, respectively. S2: Install the tool setting device below the cathode. By adjusting and coordinating the X-axis moving assembly, Y-axis moving assembly, and Z-axis moving assembly, the probe of the tool setting device is positioned in conjunction with the positioning hole on the workpiece platform, thereby accurately establishing the initial machining reference coordinates of the cathode relative to the workpiece in the X-axis and Y-axis directions. After completion, move the tool setting device out of the machining area and remove it. S3: Set the target machining gap, and drive the cathode to descend through the Z-axis moving component until the gap between the cathode and the surface of the workpiece matches the set machining gap. Start the water pump and pulse pump to allow the electrolyte to flow into the machining area through the inner cavity and outer cavity respectively. Turn on the power and apply the machining voltage between the cathode and the workpiece. S4: Under the action of an electric field, array bosses are processed by an electrolytic machining method using cathode forming. The workpiece to be processed acts as the anode and undergoes electrochemical dissolution. The dissolved part forming the boss enters the electrolyte outlet hole. The inner wall of the electrolyte outlet hole has an insulating layer to prevent the boss from being dissolved. The electrolyte flows out from the electrolyte outlet hole and washes the processing gap, carrying away the dissolved matter. During this process, the servo motor of the stirring device is started, driving the spiral blades to rotate to stir the electrolyte in the inner cavity. The outer cavity is intermittently supplied with electrolyte by a pulse pump. S5: After the array bosses at the first processing position are processed to the predetermined size, the processing power is cut off and the liquid supply is stopped; drive the X-axis moving component or the Y-axis moving component to move the electrolytic cell and the workpiece to the next preset processing position, repeat steps S3 and S4, and perform a new round of processing. This cycle continues until all array bosses on the entire workpiece are processed. S6: After all processing is completed, raise the cathode, drain the electrolyte from the electrolytic cell, remove the processed workpiece, and clean and inspect it.

[0014] In step S2, first, the Z-axis moving assembly is adjusted to lower the tool setting device; then, the X-axis and Y-axis moving assemblies are adjusted to move the positioning hole below the probe of the tool setting device; next, the Z-axis moving assembly is adjusted to lower the tool setting device to about 2mm above the positioning hole; then, the X-axis and Y-axis moving assemblies are finely adjusted to ensure that the positioning hole is accurately aligned with the probe; finally, the Z-axis moving assembly is adjusted to make the positioning hole on the workpiece platform engage with the probe of the tool setting device.

[0015] The beneficial technical effects of this invention are as follows: 1) The present invention uses a cathode feed machining method to process micro array bosses, which has the advantages of high processing depth and small taper compared with the traditional mask electrolytic machining method.

[0016] 2) The electrolyte outlet holes in the cathode of this invention adopt an array hole structure, which can be used to process bosses and ensure the discharge of electrolyte, thus realizing the cathode forming processing method.

[0017] 3) The inner wall of the electrolyte outlet hole of the present invention is provided with an insulating layer, which can prevent current from passing through and corroding the side of the pre-processed boss, thus ensuring the accuracy of the array boss. At the same time, the bottom of the outlet hole is provided with a chamfer structure, which can prevent the current from being concentrated and distributed, reduce stray corrosion, and ensure that the edge of the boss is not corroded, thereby solving the problem of large boss taper.

[0018] 4) This invention adopts a dual-cavity structure with inner and outer cavities, and the inner and outer cavities are supplied with liquid separately. This reduces the obstruction of the outer ring electrolyte to the inner ring electrolyte caused by the single-cavity structure, improves the uniformity of the electrolyte, and enables high-precision machining of micro-array bosses with small taper and large height.

[0019] 5) By setting up a stirring device, the present invention increases the flow rate of electrolyte in the inner cavity and improves the discharge efficiency of electrolysis products.

[0020] 6) The present invention uses a tool setting device and a positioning hole to eliminate positioning errors and improve the accuracy of the size, shape and position of the array bosses.

[0021] 7) This invention improves the stability of the processing process by setting up a solenoid valve to adjust the flow rate of the electrolyte in real time.

[0022] 8) This invention enables continuous processing at multiple workstations and is automatically executed through program control, thereby improving the processing efficiency of the array bosses.

[0023] 9) This machining is a cathode feed machining. As the cathode moves downward, the boss enters the electrolyte outlet hole. The wall of the electrolyte outlet hole is insulated to avoid corrosion of the side wall of the boss, thus enabling electrolytic machining of higher bosses. Attached Figure Description

[0024] Figure 1 This is a schematic diagram of the three-dimensional structure of the present invention. Figure 1 ; Figure 2 This is a schematic diagram of the three-dimensional structure of the present invention. Figure 2 ; Figure 3 This is a schematic diagram showing the connection of the cathode, stirring device, and blade setting device of the present invention; Figure 4 This is a schematic diagram of the cathode structure of the present invention; Figure 5 This is a schematic diagram of the inner tube structure of the present invention. Figure 1 ; Figure 6 This is a schematic diagram of the inner tube structure of the present invention. Figure 2 ; Figure 7 This is a schematic diagram of the structure of the outer tube of the present invention. Figure 1 ; Figure 8 This is a schematic diagram of the structure of the outer tube of the present invention. Figure 2 ; Figure 9 This is a schematic diagram of the tool setting device of the present invention. Figure 1 ; Figure 10 This is a schematic diagram of the tool setting device of the present invention. Figure 2 ; Figure 11 This is a schematic diagram of the stirring device of the present invention; Figure 12 This is a schematic diagram of the internal structure of the stirring device and cathode of the present invention; Figure 13 yes Figure 12 Enlarged view of part A; Figure 14 This is a partial structural schematic diagram of the outer tube and lower end cap of the present invention; Figure 15 This is a schematic diagram of the structure of the electrolytic cell and working platform of the present invention; Figure 16 This is a schematic diagram of the working platform of the present invention; Figure 17 This is the electrolyte pipeline of the cathode of the present invention. Figure 1 ; Figure 18 This is the electrolyte pipeline of the cathode of the present invention. Figure 2 ; Figure 19 This is a schematic diagram of the structure of the X-axis moving component of the present invention.

[0025] The labels in the above-mentioned figures are as follows: frame 1, electrolytic cell 2, workpiece platform 3, column 31, first baffle 32, positioning hole 321, second baffle 33, wedge block 34, first wire 35, cathode 4, inner cavity 4A, outer cavity 4B, electrolyte outlet 41, inner tube 42, inner cavity inlet 421, flange 422, first pipeline 423, inner cavity inlet pipe 424, outer tube 43, outer cavity inlet 431, second pipeline 432, outer cavity inlet pipe 433, pressure gauge 434, third pipeline 435. Solenoid valve 436, upper end cover 44, ring 441, lower end cover 45, groove 451, second wire 46, stirring device 5, spiral shaft 51, coupling 52, servo motor 53, spiral blade 54, motor bracket 55, X-axis moving assembly 6, motor 61, ball screw 62, screw nut 63, guide rail 64, slider 65, base 66, bellows cover 67, Y-axis moving assembly 7, Z-axis moving assembly 8, connecting beam 9, tool setting device 10, sleeve 101, probe 102, workpiece to be processed 100. Detailed Implementation

[0026] The present invention will be further described below with reference to the accompanying drawings: like Figure 1 , Figure 2 , Figure 12An electrolytic machining apparatus for an array of bosses on an integral plate is shown, comprising a frame 1, which is a rigid welded frame providing basic support for the entire apparatus. An electrolytic cell 2 is mounted on the frame 1, made of corrosion-resistant material and connected to a waste electrolyte tank via a pipeline. Inside the electrolytic cell 2 is a workpiece platform 3 for fixing the workpiece 100 to be processed. A vertically arranged cathode 4 is suspended above the workpiece platform 3. The cathode 4 is precision-manufactured from a metal material resistant to electrolytic corrosion and has a double-layer tubular structure, including an inner cavity 4A and an outer cavity 4B that are isolated from each other. The bottom of the cathode 4 has electrolyte outlet holes 41 corresponding to the inner cavity 4A and the outer cavity 4B, respectively. The workpiece platform 3 is connected to the positive terminal of a power supply via a first wire 35, and the cathode 4 is connected to the negative terminal of a power supply via a second wire 46. A processing gap is provided between the cathode 4 and the workpiece 100 for electrolyte flow; in this embodiment, the processing gap is 0.5 mm.

[0027] Furthermore, such as Figures 3-8 , Figures 12-14 As shown, the cathode 4 has a stepped structure, including an inner tube 42 and an outer tube 43 arranged concentrically. The length of the outer tube 43 is shorter than that of the inner tube 42, meaning that the outer tube 43 and the inner tube 42 have a partially nested section. The top of the inner tube 42 is provided with an upper end cap 44 that is sealed to it. The bottom of the inner tube 42 is open and this end is fixed to the lower end cap 45 of the outer tube 43. A flange 422 is provided on the outer wall of the inner tube 42. The top of the outer tube 43 is open and this end is bolted to the flange 422. The bottom of the outer tube 43 is integrally formed with it. The lower end cap 45 has a groove 451 at its top that fits into the bottom of the inner tube 42. The bottom of the lower end cap 45 extends out of the outer tube 43. Electrolyte outlet holes 41 are provided through the lower end cap 45 and are arranged in a radial array from the center of the lower end cap 45. An inner cavity 4A is formed between the inner tube 42, the upper end cap 44, and the lower end cap 45. An outer cavity 4B is formed between the outer tube 43, the flange 422, the lower end cap 45, and the inner tube 42 nested with the outer tube 43. In this embodiment, the outermost ring of electrolyte outlet holes 41 on the lower end cap 45 corresponds to the outer cavity 4B, and the remaining rings of electrolyte outlet holes 41 correspond to the inner cavity 4A.

[0028] Furthermore, such as Figure 17 , Figure 18As shown, the inner cavity 4A and the outer cavity 4B are respectively connected to the electrolyte supply tank through pipelines. Specifically, the inner tube 42 has two symmetrical inner cavity inlets 421, which are connected by a first pipeline 423. The first pipeline 423 is connected to the electrolyte supply tank through an inner cavity inlet pipe 424 and a water pump. The outer tube 43 has two symmetrical outer cavity inlets 431, which are connected by a second pipeline 432. The second pipeline 432 is connected to the outer cavity inlet pipe 433, which is connected to a pulse pump. A third pipeline 435, which is connected to the electrolyte supply tank, is bypassed by the outer cavity inlet pipe 433. A solenoid valve 436 is connected to the third pipeline 435, which can adjust the supply pressure in the outer cavity 4B. A pressure gauge 434 is also connected to the outer cavity inlet pipe 433. The electrolyte enters the inner cavity 4A and the outer cavity 4B through the inner cavity inlet 421 and the outer cavity inlet 431 respectively, and then flows out through the corresponding electrolyte outlet 41.

[0029] In this embodiment, the inner cavity 4A and outer cavity 4B, which are isolated from each other, are supplied with electrolyte separately. This reduces the obstruction of the outer ring electrolyte to the discharge of the inner ring electrolyte. The outer cavity inlet pipe 433 uses a pulse pump for electrolyte supply, which has intermittent characteristics. When a high-voltage pulse is generated, a large amount of electrolyte is injected at high speed into the outer ring machining gap. While powerfully flushing this area, it generates a periodic additional suction force on the electrolyte flowing out of the inner ring, providing an active and enhanced external driving force for the discharge of waste liquid from the inner ring. At the same time, during the low-pressure or intermittent phases of the pulse cycle, the outflow from the outer ring is significantly reduced, allowing the inner ring electrolyte to be discharged under its own pressure without interference from the outer ring electrolyte.

[0030] In this embodiment, the inner cavity 4A and outer cavity 4B of the cathode 4 employ two independent electrolyte flow channels. Specifically, the electrolyte flows into the inner cavity inlet pipe 424, then is split into two paths via the first pipe 423, flowing into the inner cavity 4A of the cathode 4 from the two inner cavity inlets 421, and then out through the electrolyte outlet holes 41 corresponding to the inner cavity 4A, forming the inner electrolyte flow channel. The electrolyte flows into the outer cavity inlet pipe 433, then is split into two paths via the second pipe 432, flowing into the outer cavity 4B of the cathode 4 from the two outer cavity inlets 431, and then out through the electrolyte outlet holes 41 corresponding to the outer cavity 4B, forming the outer electrolyte flow channel. This independent flow channel avoids interference from the electrolyte discharged from the outer ring to the fresh electrolyte in the inner ring, reducing the obstruction of the outer ring electrolyte discharge and allowing for smoother electrolyte flow.

[0031] In this embodiment, the cathode 4, the first pipeline 423, the second pipeline 432, the third pipeline 435, the inner cavity liquid inlet pipe 424, the outer cavity liquid inlet pipe 433, and the pressure gauge 434 are all fixed to the connecting beam 9 by clamp-type fixtures.

[0032] Furthermore, such as Figure 12 As shown, a dense insulating layer is provided on the inner wall of the electrolyte outlet hole 41 to prevent current from passing through and corroding the side of the pre-machined boss, thus ensuring the accuracy of the array boss; the bottom of the electrolyte outlet hole 41 is machined with a chamfer with a radius of 0.2mm to prevent current from being concentrated and distributed, reduce stray corrosion, and ensure that the edges of the boss are not corroded, thereby solving the problem of large boss taper.

[0033] Furthermore, such as Figure 9 , Figure 10 As shown, the bottom of the cathode 4 is also provided with a tool setting device 10 that is detachably fixed thereto. The tool setting device 10 includes a sleeve 101 and a probe 102 located at the center of the bottom of the sleeve 101. The sleeve 101 is fitted onto the lower end cover 45 and is a hollow cylindrical body with an open top. The probe 102 includes a first cylinder, a second cylinder, and a cone arranged sequentially from top to bottom. The first baffle 32 is provided with a positioning hole 321 that mates with the apex of the cone. Before the machining begins, the Z-axis moving assembly 8 is controlled to lower the tool setting device, and then the X-axis moving assembly 6 and the Y-axis moving assembly 7 are driven to make the probe 102 mate with the positioning hole 321. The control system records the coordinates of these two positions to accurately establish the coordinate relationship between the center of the electrolyte outlet holes 41 arranged in an array on the cathode 4 and the machining area of ​​the workpiece 100.

[0034] Furthermore, such as Figure 11 , Figure 12 As shown, an agitator 5 is installed inside the inner cavity 4A. The agitator 5 includes a spiral shaft 51 that passes through the upper end cover 44. The spiral shaft 51 is connected to a servo motor 53 via a coupling 52. Spiral blades 54 are fixed on the spiral shaft 51 located inside the inner cavity 4A. Specifically, the upper end cover 44 has a through hole for the spiral shaft 51 to pass through. A ring 441 is embedded in the through hole. The inner wall of the ring 441 is provided with a polytetrafluoroethylene lubricating layer. The servo motor 53 is fixed to the upper end cover 44 via a motor bracket 55. The agitator 5 can achieve active, constant-speed rotation to agitate the inner electrolyte and increase the electrolyte flow rate.

[0035] Furthermore, such as Figure 15 , Figure 16As shown, the workpiece platform 3 is made of insulating material. The workpiece platform 3 is connected to the electrolytic cell 2 via a column 31. A first baffle 32 and a second baffle 33 are vertically mounted at both ends of the workpiece platform 3. The first baffle 32 and the second baffle 33 are integrally formed with the workpiece platform 3. One end of the workpiece 100 is positioned against the first baffle 32, and a pair of wedge blocks 34 are provided between the other end of the workpiece 100 and the second baffle 33. The workpiece 100 is clamped on the workpiece platform 3 by adjusting the position of the wedge blocks 34. Specifically, the wedge block 34 includes a first wedge block 341 and a second wedge block 342. The first wedge block 341 abuts against the end of the workpiece 100 near the second baffle 33, and the second wedge block 342 is fixed to the workpiece platform 3 by adjusting bolts. The wedge surfaces of the first wedge block 341 and the second wedge block 342 abut against each other. The workpiece 100 is clamped on the workpiece platform 3 by tightening the adjusting bolts.

[0036] Furthermore, the horizontal position of the electrolytic cell 2 on the frame 1 is adjustable, and the height of the cathode 4 from the workpiece platform 3 is adjustable. Specifically, the horizontal position of the electrolytic cell 2 is adjusted via the X-axis moving assembly 6 and the Y-axis moving assembly 7, while the height of the cathode 4 is adjusted via the Z-axis moving assembly 8. The X-axis moving assembly 6, the Y-axis moving assembly 7, and the Z-axis moving assembly 8 constitute a three-dimensional motion platform. This three-dimensional motion platform can be implemented using various structures from existing technologies, which will not be elaborated upon here.

[0037] In this embodiment, the X-axis moving assembly 6, the Y-axis moving assembly 7, and the Z-axis moving assembly 8 all employ a combination of ball screw pairs and linear guide pairs, such as... Figure 19 As shown, taking the X-axis moving assembly as an example, it includes components such as a motor 61, a ball screw 62, a screw nut 63, a guide rail 64, a slider 65, and a base 66. The specific structure can be found in existing technology. The Y-axis moving assembly 7 and the Z-axis moving assembly 8 are both fixed to the frame 1. The base of the X-axis moving assembly 6 is fixed to the slider and screw nut of the Y-axis moving assembly 7. The electrolytic cell 2 is fixed to the slider and screw nut of the X-axis moving assembly 6. The cathode 4 is fixed to the slider and screw nut of the Z-axis moving assembly 8 via a connecting beam 9. The X-axis moving assembly 6, Y-axis moving assembly 7, and Z-axis moving assembly 8 are also equipped with bellows covers 67 to effectively prevent dust.

[0038] The working principle of this invention is: This invention relates to an electrolytic machining apparatus for creating array bosses on integral sheet metal parts. Its working principle is as follows: the array bosses are machined using the electrochemical anodic dissolution principle of metal in an electrolyte, through cathode forming. The workpiece is fixed on a support platform, and the tool setting device is adjusted to determine the position of the cathode center relative to the workpiece. The workpiece and cathode are connected to the positive and negative terminals of the power supply, respectively. The cathode position is adjusted to the target machining gap, and the electrolyte pump and power supply are started. A suitable speed is set through a control program to lower the cathode to the appropriate position, dissolving the workpiece and machining the array bosses.

[0039] The present invention also provides a processing method for an electrolytic machining apparatus for an array of bosses on an integral plate, comprising the following steps: S1: After cleaning the workpiece, place it on the workpiece platform and clamp it on the workpiece platform with wedge blocks. Connect the first wire and the second wire to the positive and negative terminals of the power supply, respectively. S2: Install the tool setting device below the cathode. By adjusting and coordinating the X-axis moving assembly, Y-axis moving assembly, and Z-axis moving assembly, the probe of the tool setting device is positioned in conjunction with the positioning hole on the workpiece platform, thereby accurately establishing the initial machining reference coordinates of the cathode relative to the workpiece in the X-axis and Y-axis directions. After completion, move the tool setting device out of the machining area and remove it. S3: Set the target machining gap, and drive the cathode to descend through the Z-axis moving component until the gap between the cathode and the surface of the workpiece matches the set machining gap. Start the water pump and pulse pump to allow the electrolyte to flow into the machining area through the inner cavity and outer cavity respectively. Turn on the power and apply the machining voltage between the cathode and the workpiece. S4: Under the action of an electric field, array bosses are processed by an electrolytic machining method using cathode forming. The workpiece to be processed acts as the anode and undergoes electrochemical dissolution. The dissolved part forming the boss enters the electrolyte outlet hole. The inner wall of the electrolyte outlet hole has an insulating layer to prevent the boss from being dissolved. The electrolyte flows out from the electrolyte outlet hole and washes the processing gap, carrying away the dissolved matter. During this process, the servo motor of the stirring device is started, driving the spiral blades to rotate to stir the electrolyte in the inner cavity. The outer cavity is intermittently supplied with electrolyte by a pulse pump. S5: After the array bosses at the first processing position are processed to the predetermined size, the processing power is cut off and the liquid supply is stopped; drive the X-axis moving component or the Y-axis moving component to move the electrolytic cell and the workpiece to the next preset processing position, repeat steps S3 and S4, and perform a new round of processing. This cycle continues until all array bosses on the entire workpiece are processed. S6: After all processing is completed, raise the cathode, drain the electrolyte from the electrolytic cell, remove the processed workpiece, and clean and inspect it.

[0040] In step S2, first adjust the Z-axis moving assembly to lower the tool setting device; then adjust the X-axis and Y-axis moving assemblies to move the positioning hole below the probe of the tool setting device; next, adjust the Z-axis moving assembly to lower the tool setting device to about 2mm above the positioning hole; then fine-tune the X-axis and Y-axis moving assemblies to ensure that the positioning hole is accurately aligned with the probe; finally, adjust the Z-axis moving assembly to make the positioning hole on the workpiece platform engage with the probe of the tool setting device.

[0041] The embodiments described above are merely preferred embodiments of the present invention and are not intended to limit the scope of the present invention. Various modifications and improvements made by those skilled in the art to the technical solutions of the present invention without departing from the spirit of the present invention should fall within the protection scope defined by the claims of the present invention.

Claims

1. An electrolytic machining apparatus for an array of bosses on an integral sheet metal part, characterized in that: The device includes a frame (1), on which an electrolytic cell (2) is provided. The electrolytic cell (2) contains a workpiece platform (3) for fixing the workpiece (100) to be processed. A cathode (4) is suspended above the workpiece platform (3) in a vertical direction. The cathode (4) has a double-layer tubular structure, including an inner cavity (4A) and an outer cavity (4B) that are isolated from each other. The inner cavity (4A) and the outer cavity (4B) are respectively connected to the electrolyte supply tank through pipelines. The bottom of the cathode (4) is provided with electrolyte outlet holes (41) corresponding to the inner cavity (4A) and the outer cavity (4B) respectively. The electrolyte enters the inner cavity (4A) and the outer cavity (4B). The electrolyte (4B) flows out through the corresponding electrolyte outlet hole (41) after being processed. The inner wall of the electrolyte outlet hole (41) is provided with an insulating layer, and the bottom of the electrolyte outlet hole (41) is chamfered. The workpiece platform (3) is connected to the positive terminal of the power supply through the first wire (35), and the cathode (4) is connected to the negative terminal of the power supply through the second wire (46). There is a processing gap between the cathode (4) and the workpiece (100) to be processed to allow the electrolyte to flow. The electrolytic cell (2) is connected to the waste electrolyte tank through a pipeline. The horizontal position of the electrolytic cell (2) on the frame (1) is adjustable, and the height position of the cathode (4) from the workpiece platform (3) is adjustable.

2. The electrolytic machining apparatus for an array of bosses on an integral plate as described in claim 1, characterized in that: The cathode (4) has a stepped structure, including an inner tube (42) and an outer tube (43) arranged concentrically. The length of the outer tube (43) is shorter than that of the inner tube (42). The top of the inner tube (42) is provided with an upper end cap (44) that is sealed to it. The bottom of the inner tube (42) is open and is fixed to the lower end cap (45) of the outer tube (43). A flange (422) is provided on the outer wall of the inner tube (42). The top of the outer tube (43) is open and is bolted to the flange (422). The bottom of the outer tube (43) is provided with a lower end cap (45) integrally formed with it. The top of (45) is provided with a groove (451) that is inserted into the bottom of the inner tube (42). The bottom of the lower end cover (45) extends out of the outer tube (43). The electrolyte outlet hole (41) is provided through the lower end cover (45) and the electrolyte outlet hole (41) is arranged in a radial array from the center of the lower end cover (45). An inner cavity (4A) is formed between the inner tube (42), the upper end cover (44) and the lower end cover (45). An outer cavity (4B) is formed between the outer tube (43), the flange (422), the lower end cover (45) and the inner tube (42) nested with the outer tube (43).

3. The electrolytic machining apparatus for an array of bosses on an integral plate as described in claim 2, characterized in that: The inner tube (42) is symmetrically provided with two inner cavity liquid inlets (421), and the two inner cavity liquid inlets (421) are connected by a first pipeline (423). The first pipeline (423) is connected to the electrolyte supply tank in sequence through the inner cavity liquid inlet pipe (424) and the water pump. The outer tube (43) is symmetrically provided with two external cavity liquid inlets (431), and the two external cavity liquid inlets (431) are connected by a second pipe (432). The second pipe (432) is connected to the external cavity liquid inlet pipe (433), and the external cavity liquid inlet pipe (433) is connected to a pulse pump. A pressure gauge (434) is also connected to the external cavity liquid inlet pipe (433). A third pipe (435) connected to the electrolyte supply tank is bypassed on the external cavity liquid inlet pipe (433), and a solenoid valve (436) is connected to the third pipe (435).

4. The electrolytic machining apparatus for an array of bosses on an integral plate as described in claim 1, characterized in that: The inner cavity (4A) is provided with a stirring device (5), which includes a spiral shaft (51) that passes through the upper end cover (44). The spiral shaft (51) is connected to a servo motor (53) through a coupling (52). Spiral blades (54) are fixed on the spiral shaft (51) located in the inner cavity (4A). The upper end cover (44) has a through hole for the spiral shaft (51) to pass through. A ring (441) is embedded in the through hole. The inner wall of the ring (441) is provided with a lubricating layer. The servo motor (53) is fixed on the upper end cover (44) by a motor bracket (55).

5. The electrolytic machining apparatus for an array of bosses on an integral plate as described in claim 1, characterized in that: The bottom of the cathode (4) is also provided with a tool setting device (10) that can be detachably fixed thereto. The tool setting device (10) includes a sleeve (101) and a probe (102) set at the center of the bottom of the sleeve (101). The sleeve (101) is fitted on the lower end cover (45), and the sleeve (101) is a hollow column with an open top. The probe (102) includes a first cylinder, a second cylinder and a cone arranged sequentially from top to bottom. The first baffle (32) is provided with a positioning hole (321) that matches the apex of the cone.

6. The electrolytic machining apparatus for an array of bosses on an integral plate as described in claim 1, characterized in that: The workpiece platform (3) is connected to the electrolytic cell (2) by a column (31). The two ends of the workpiece platform (3) are respectively provided with a first baffle (32) and a second baffle (33). The first baffle (32) and the second baffle (33) are integrally formed with the workpiece platform (3). One end of the workpiece (100) is positioned against the first baffle (32). The other end of the workpiece (100) is provided with a pair of wedge blocks (34) that cooperate with the second baffle (33). The workpiece (100) is clamped on the workpiece platform (3) by adjusting the position of the wedge blocks (34).

7. The electrolytic machining apparatus for an array of bosses on an integral plate as described in claim 1, characterized in that: The electrolytic cell (2) is adjusted in horizontal position by means of X-axis moving component (6) and Y-axis moving component (7), and the cathode (4) is adjusted in height position by means of Z-axis moving component (8). The X-axis moving component (6), Y-axis moving component (7) and Z-axis moving component (8) are all combinations of ball screw pair and linear guide pair. The Y-axis moving component (7) and Z-axis moving component (8) are both fixed on the frame (1).

8. The electrolytic machining apparatus for an array of bosses on an integral plate as described in claim 3, characterized in that: The cathode (4), the first pipeline (423), the second pipeline (432), the third pipeline (435), the inner cavity liquid inlet pipe (424), the outer cavity liquid inlet pipe (433), and the pressure gauge (434) are all fixed to the connecting beam (9) by clamps.

9. A processing method for an electrolytic machining apparatus for an array of bosses on an integral sheet metal part according to any one of claims 1 to 8, comprising the following steps: S1: After cleaning the workpiece, place it on the workpiece platform and clamp it on the workpiece platform with wedge blocks. Connect the first wire and the second wire to the positive and negative terminals of the power supply, respectively. S2: Install the tool setting device below the cathode. By adjusting and coordinating the X-axis moving assembly, Y-axis moving assembly, and Z-axis moving assembly, the probe of the tool setting device is positioned in conjunction with the positioning hole on the workpiece platform, thereby accurately establishing the initial machining reference coordinates of the cathode relative to the workpiece in the X-axis and Y-axis directions. After completion, move the tool setting device out of the machining area and remove it. S3: Set the target machining gap, and drive the cathode to descend through the Z-axis moving component until the gap between the cathode and the surface of the workpiece matches the set machining gap. Start the water pump and pulse pump to allow the electrolyte to flow into the machining area through the inner cavity and outer cavity respectively. Turn on the power and apply the machining voltage between the cathode and the workpiece. S4: Under the action of an electric field, array bosses are processed by an electrolytic machining method using cathode forming. The workpiece to be processed acts as the anode and undergoes electrochemical dissolution. The dissolved part forming the boss enters the electrolyte outlet hole. The inner wall of the electrolyte outlet hole has an insulating layer to prevent the boss from being dissolved. The electrolyte flows out from the electrolyte outlet hole and washes the processing gap, carrying away the dissolved matter. During this process, the servo motor of the stirring device is started, driving the spiral blades to rotate to stir the electrolyte in the inner cavity. The outer cavity is intermittently supplied with electrolyte by a pulse pump. S5: After the array bosses at the first processing position are processed to the predetermined size, the processing power is cut off and the liquid supply is stopped; drive the X-axis moving component or the Y-axis moving component to move the electrolytic cell and the workpiece to the next preset processing position, repeat steps S3 and S4, and perform a new round of processing. This cycle continues until all array bosses on the entire workpiece are processed. S6: After all processing is completed, raise the cathode, drain the electrolyte from the electrolytic cell, remove the processed workpiece, and clean and inspect it.

10. The processing method of the electrolytic machining apparatus for integral plate array bosses according to claim 9, characterized in that: In step S2, the Z-axis moving component is first adjusted to lower the tool setting device; Next, adjust the X-axis and Y-axis moving components to move the positioning hole below the probe of the tool setting device; then adjust the Z-axis moving component to lower the tool setting device to about 2mm above the positioning hole; then fine-tune the X-axis and Y-axis moving components to ensure that the positioning hole is accurately aligned with the probe; finally, adjust the Z-axis moving component to make the positioning hole on the workpiece platform engage with the probe of the tool setting device.

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