Electrochemical machining device and method for machining a composite housing boss

Abstract

The application discloses a composite casing boss electrolytic machining device and a machining method thereof, and belongs to the field of electrolytic machining equipment. The device comprises a cathode base, first and second cathode mounting seats and a plurality of cathodes with different sizes. The cathodes are coaxially sleeved through hollow structures, and the inner hole sizes are matched with the outer shape sizes of the casing bosses to be machined. The plurality of cathodes with different sizes can be selectively fixed on the mounting seats, so that the casing bosses with different sizes can be machined in the same device. Electrolyte enters the hollow cavities of the plurality of cathodes through a liquid inlet and is directly sprayed to machining positions of the bosses to be machined. The fixing state of the cathodes is adjusted, the whole cathode device is avoided from being replaced, and continuous electrolytic machining of the casing bosses with different sizes is realized.

Description

Technical Field

[0001] This application relates to the field of electrolytic machining equipment, specifically to a composite casing boss electrolytic machining apparatus and machining method. Background Technology

[0002] In traditional electrochemical machining (ECM) equipment, when machining casing bosses of different sizes, it is usually necessary to change to different cathode devices according to the different boss sizes. This not only increases the changeover time and labor costs during the machining process, but also may lead to instability in machining accuracy and a reduction in machining efficiency during cathode replacement. Furthermore, ensuring that the electrolyte effectively acts on the target machining area while avoiding corrosion of non-machined areas is also a problem that urgently needs to be solved.

[0003] Existing electrochemical machining (ECM) equipment often uses a single-sized cathode for machining bosses of various sizes. This design cannot adapt to the machining requirements of different sizes, resulting in a cumbersome and inefficient process. Furthermore, the cathode fixing method and electrolyte flow structure in traditional equipment are relatively simple, making it difficult to achieve precise liquid jetting and a stable machining process. Therefore, how to achieve electrochemical machining of bosses of different sizes without replacing the entire cathode assembly has become a pressing technical problem in the field of ECM.

[0004] The technical solution of this application addresses this problem by proposing a composite casing boss electrolytic machining device and its machining method. By using multiple hollow cathodes of different sizes that can be selectively fixed, it not only solves the problem of switching between machining of casing bosses of different sizes, but also effectively improves the electrolyte spraying accuracy and machining efficiency. Summary of the Invention

[0005] This application provides a composite electrolytic machining apparatus and method for casing bosses, which solves the problem that traditional electrolytic machining apparatuses need to change the cathode device when processing casing bosses of different sizes, thereby improving machining efficiency.

[0006] According to one aspect of this application, a composite casing boss electrolytic machining apparatus is provided, including a cathode base, a first cathode mounting base, a second cathode mounting base, and a plurality of cathodes of different sizes. The first cathode mounting base and the second cathode mounting base are connected along the machining direction to form a mounting cavity, and a plurality of cathodes of different sizes are provided in the mounting cavity. Multiple cathodes of different sizes are hollow structures and are coaxially stacked in order of increasing size. The hollow cavities of the multiple cathodes of different sizes are used to process casing bosses of different sizes. Each cathode can be selectively fixed to the first cathode mounting base or the second cathode mounting base, so that the cathode corresponding to the size of the machine housing boss to be processed is located on the processing side and serves as the main processing cathode, while the cathode with a size smaller than the main processing cathode is switched to the side away from the processing side. The cathode base is provided with an inlet for the electrolyte to enter. The hollow cavities of multiple cathodes of different sizes together form an electrolyte channel that communicates with the inlet. The electrolyte channel is used to guide the electrolyte to the processing part of the casing boss to be processed.

[0007] Optionally, multiple cathodes of different sizes include a first cathode, a second cathode, and a third cathode, with the inner diameters of the first cathode, the second cathode, and the third cathode increasing sequentially. When the first cathode is used as the main processing cathode, the first cathode, the second cathode, and the third cathode are all fixed on the second cathode mounting base. When the second cathode is used as the main processing cathode, the first cathode is fixed on the first cathode mounting base, and the second cathode and the third cathode are jointly fixed on the second cathode mounting base; When the third cathode is used as the main processing cathode, the first cathode and the second cathode are fixed together on the first cathode mounting base, and the third cathode is fixed on the second cathode mounting base.

[0008] Optionally, the first cathode mounting base and the second cathode mounting base are respectively provided with mounting holes, and the first cathode, the second cathode and the third cathode are respectively provided with threaded holes and clearance holes. When different cathodes are used as the main processed cathodes, the fastener passes through the mounting holes on the corresponding cathode mounting base and the clearance holes on the corresponding cathode, and then connects with the threaded holes on the corresponding cathode, so as to achieve selective fixing of the first cathode, the second cathode and the third cathode on the first cathode mounting base and the second cathode mounting base.

[0009] Optionally, the first cathode mounting base is provided with a first mounting hole, and the second cathode mounting base is provided with a second mounting hole; the first cathode is provided with a first threaded hole, a first gap hole and a second gap hole, the second cathode is provided with a second threaded hole, a third gap hole and a fourth gap hole, and the third cathode is provided with a third threaded hole, a fifth gap hole and a sixth gap hole; When the first cathode is used as the main machining cathode, the fastener passes through the second mounting hole, the fifth clearance hole and the third clearance hole and then connects to the first threaded hole to fix the first cathode, the second cathode and the third cathode on the second cathode mounting base; When the second cathode is used as the main machining cathode, the first cathode is connected to the first threaded hole through the first mounting hole and fixed on the first cathode mounting base. The second cathode and the third cathode are connected to the second threaded hole through the second mounting hole and the sixth gap hole and fixed on the second cathode mounting base. When the third cathode is used as the main machining cathode, the fastener passes through the first mounting hole and the second clearance hole and connects to the second threaded hole to fix the first cathode and the second cathode on the first cathode mounting base. The third cathode is connected to the third threaded hole through the second mounting hole and fixed on the second cathode mounting base.

[0010] Optionally, each cathode inner surface and / or outer surface is provided with an insulating layer, which avoids the electrolytic machining part of the corresponding housing boss to be machined, so as to form an exposed machining working surface.

[0011] Optionally, it also includes a component base for fixing the component, which is connected to the positive terminal of the power supply.

[0012] According to another aspect of this application, a method for electrolytic machining of composite casing bosses is also provided, comprising the following steps: S1, multiple hollow cathodes of different sizes are coaxially stacked in order of increasing size and installed into the mounting cavity formed by the first cathode mounting base and the second cathode mounting base; S2. Based on the size of the machine casing boss to be processed, select a cathode whose inner hole size matches the outer size of the machine casing boss to be processed as the main processing cathode, and switch the cathode with a size smaller than the main processing cathode to the side away from the processing side and fix it. S3, connect the first cathode mounting base, the second cathode mounting base and the cathode base to complete the cathode device assembly; S4, clamp and position the casing so that the casing boss to be processed is aligned with the main machining cathode; S5, Electrolyte is introduced into the inlet, so that the electrolyte is directly sprayed onto the machining part of the casing boss to be processed through the electrolyte channel formed by the hollow inner cavity of multiple cathodes of different sizes, and electrolytic machining is performed. S6, after completing the machining of a casing boss of one size, the fixing states of multiple cathodes of different sizes on the first cathode mounting base and the second cathode mounting base are changed to achieve the electrolytic machining of a casing boss of another size.

[0013] Optionally, the multiple cathodes include a first cathode, a second cathode, and a third cathode. When machining the smallest size casing boss, the first cathode, the second cathode, and the third cathode are fixed together on the second cathode mounting base, and the first cathode is used as the main machining cathode for machining. When machining the casing boss of intermediate size, the first cathode is fixed on the first cathode mounting base, and the second cathode and the third cathode are jointly fixed on the second cathode mounting base, with the second cathode serving as the main machining cathode for machining; When machining the largest size casing boss, the first cathode and the second cathode are fixed together on the first cathode mounting base, and the third cathode is fixed on the second cathode mounting base. The third cathode is used as the main machining cathode for machining.

[0014] Optionally, when machining multiple casing bosses of different sizes, electrolytic machining is performed sequentially according to the size of the casing bosses from small to large or from large to small. Between machining of two adjacent casing bosses of different sizes, the machining is switched by changing the fixed state of multiple cathodes of different sizes on the first cathode mounting base and the second cathode mounting base.

[0015] Optionally, during electrolytic machining, a main machining cathode that matches the size of the machine casing boss to be machined is fitted around the outer periphery of the machine casing boss to be machined, so that a corresponding annular machining gap is formed between the main machining cathode and the machine casing boss to be machined.

[0016] In summary, this application includes at least one of the following beneficial technical effects: This solution designs a composite electrolytic machining device for casing bosses, employing multiple hollow cathodes of different sizes. Through selective fixing, these cathodes can be adapted to casing bosses of varying sizes. The hollow structure and sleeve design of the multiple cathodes allow smaller cathodes to be nested within larger cathodes, forming a cathode combination suitable for different casing boss sizes. Furthermore, the cathodes can be selectively fixed to either the first or second cathode mounting base, depending on the size of the boss to be machined, ensuring a dimensional match between the main machining cathode and the casing boss. This allows for rapid switching between electrolytic machining of different casing boss sizes without replacing the entire cathode assembly, simply by changing the cathode's fixing position. In addition, the electrolyte enters the hollow cavity of the cathode through the inlet, forming an electrolyte channel that is directly sprayed onto the machining area of ​​the casing boss, ensuring precise application of the electrolyte to the machining area and improving machining efficiency and accuracy. This design not only solves the drawback of traditional methods requiring cathode assembly replacement but also ensures precise electrolyte spraying, further optimizing the electrolytic machining process.

[0017] In addition to the purposes, features, and advantages described above, this application has other purposes, features, and advantages. A further detailed description of this application will be provided below with reference to the figures. Attached Figure Description

[0018] The accompanying drawings, which form part of this application, are used to provide a further understanding of this application. The illustrative embodiments and descriptions of this application are used to explain this application and do not constitute an undue limitation of this application. In the drawings: Figure 1 This is a sectional view of the tooling used for electrolytic machining of the casing boss in this application; Figure 2 This is the general drawing of the tooling for electrolytic machining of the casing boss in this application; Figure 3 This is a schematic diagram of the electrolytic machining apparatus for the first boss in this application; Figure 4 This is a schematic diagram of the electrolytic machining apparatus for the second boss in this application; Figure 5 This is a schematic diagram of the electrolytic machining apparatus for the third boss in this application; Figure 6 This is a schematic diagram of the first cathode aperture position in this application; Figure 7 This is a schematic diagram of the second cathode aperture position in this application; Figure 8 This is a schematic diagram of the third cathode aperture position in this application; Figure 9 This is a schematic diagram of the hole positions of the first cathode mounting base in this application; Figure 10 This is a schematic diagram of the hole positions of the second cathode mounting base in this application; Figure 11 This is a schematic diagram of the casing boss in this application.

[0019] Legend: 1. Cathode base; 2. First cathode mounting base; 3. Second cathode mounting base; 4. Cover plate; 5. Compression nut; 6. Center stud; 7. Casing; 8. Part base; 9. Third cathode; 10. Second cathode; 11. First cathode; 12. Insulating layer; 13. First boss; 14. Second boss; 15. Third boss; 16. First mounting hole; 17. Second mounting hole; 18. First threaded hole; 19. First clearance hole; 20. Second clearance hole; 21. Third clearance hole; 22. Second threaded hole; 23. Fourth clearance hole; 24. Third threaded hole; 25. Fifth clearance hole; 26. Sixth clearance hole; 27. Liquid inlet. Detailed Implementation

[0020] The embodiments of this application are described in detail below with reference to the accompanying drawings; however, this application may be implemented in a variety of different ways as defined and covered below.

[0021] The following is in conjunction with the appendix Figure 1-11 This application will be described in further detail.

[0022] This application discloses an electrolytic machining apparatus and method for composite casing bosses.

[0023] Reference Figure 1This application discloses a composite casing boss electrolytic machining apparatus, including a cathode base 1, a first cathode mounting base 2, a second cathode mounting base 3, and multiple cathodes of different sizes. The first cathode mounting base 2 and the second cathode mounting base 3 are connected to form an inner cavity for accommodating multiple cathodes of different sizes. The multiple cathodes of different sizes are all hollow structures and are coaxially stacked in order of increasing size, with the smaller cathodes located inside the larger cathodes. The inner hole size of each cathode is adapted to the outer dimensions of the corresponding casing boss to be machined. Each cathode can be selectively fixed to the first cathode mounting base 2 or the second cathode mounting base 3, so that the cathode corresponding to the size of the casing boss to be machined is located on the machining side and serves as the main machining cathode, while the cathode smaller than the main machining cathode is switched to the side away from the machining side. The cathode base 1 is provided with an inlet 27 for the entry of electrolyte. The hollow inner cavities of the multiple cathodes of different sizes together form an electrolyte channel communicating with the inlet 27. The electrolyte channel is used to guide the electrolyte to the machining part of the casing boss to be machined.

[0024] In this embodiment, multiple hollow cathodes of different sizes are used to ensure that the inner diameter of each cathode matches the outer diameter of the casing boss to be processed. The cathodes employ a coaxial stacking design, with the smaller cathode nested inside the larger cathode, forming a cathode assembly capable of accommodating casing bosses of different sizes. When processing casing bosses of different sizes, the fixing state of the cathodes can be adjusted according to the size of the boss to be processed, ensuring that the cathode matching the target casing boss size is always located on the processing side and serves as the main processing cathode, while the smaller cathode is moved to the side away from the processing side. This design avoids the problem of replacing the entire cathode assembly each time a different size boss is processed, enabling continuous processing of casing bosses of multiple sizes.

[0025] Electrolyte enters the hollow cavities of multiple cathodes through the inlet 27 on the cathode base 1. The electrolyte, flowing through the electrolyte channels formed by these cavities, is directly sprayed onto the machining area of ​​the casing boss. This allows the electrolyte to act precisely on the machining area, avoiding the problems of uneven electrolyte flow or waste in traditional electrochemical machining, thus improving machining accuracy and efficiency. The selective fixing method allows cathodes of different sizes to be adjusted according to machining requirements without replacing the entire cathode assembly. This design enables electrochemical machining of casing bosses of different sizes on the same equipment, greatly improving equipment flexibility and machining efficiency. The elimination of frequent cathode assembly replacements simplifies the operation process, reduces equipment changeover time and labor costs, and also improves stability during machining.

[0026] Reference Figure 2 and Figure 3In one embodiment, multiple cathodes of different sizes include a first cathode 11, a second cathode 10, and a third cathode 9. The outer circle of the first cathode 11 is disposed within the inner circle of the second cathode 10, and the outer circle of the second cathode 10 is disposed within the inner circle of the third cathode 9. The first cathode 11, the second cathode 10, and the third cathode 9 are stacked together in the mounting cavity. When the first cathode 11 is used as the main processing cathode, the first cathode 11, the second cathode 10, and the third cathode 9 are all fixed to the second cathode mounting base 3. When the second cathode 10 is used as the main processing cathode, the first cathode 11 is fixed to the first cathode mounting base 2, and the second cathode 10 and the third cathode 9 are both fixed to the second cathode mounting base 3. When the third cathode 9 is used as the main processing cathode, the first cathode 11 and the second cathode 10 are both fixed to the first cathode mounting base 2, and the third cathode 9 is fixed to the second cathode mounting base 3.

[0027] Multiple hollow cathodes of different sizes are coaxially stacked in sequence, with smaller cathodes nested inside larger cathodes, forming a compact cathode assembly. Specifically, the outer circle of the first cathode 11 is set within the inner circle of the second cathode 10, and the outer circle of the second cathode 10 is set within the inner circle of the third cathode 9. The three cathodes are stacked together in the mounting cavity in a coaxial manner. This design allows the position and fixing state of cathodes of different sizes to be selectively adjusted according to the size of the casing boss to be processed during operation, so as to perform electrolytic machining on casing bosses of different sizes.

[0028] When the first cathode 11 is used as the main processing cathode, the first cathode 11, the second cathode 10, and the third cathode 9 are all fixed on the second cathode mounting base 3, thus forming a complete electrolytic processing area. When the second cathode 10 is used as the main processing cathode, the first cathode 11 is fixed on the first cathode mounting base 2, while the second cathode 10 and the third cathode 9 are both fixed on the second cathode mounting base 3, forming another processing configuration. When the third cathode 9 is used as the main processing cathode, the first cathode 11 and the second cathode 10 are both fixed on the first cathode mounting base 2, and the third cathode 9 is fixed on the second cathode mounting base 3, ensuring the stability and accuracy of the processing area. The nested design between the cathodes not only effectively reduces the space occupied by the equipment but also improves the processing accuracy because the inner hole size of each cathode matches the outer dimensions of the casing boss to be processed, ensuring that the electrolyte can be accurately sprayed onto the processing area, thus improving the stability and effect of electrolytic processing.

[0029] Reference Figure 5 and Figure 6In one embodiment, the first cathode mounting base 2 and the second cathode mounting base 3 are respectively provided with mounting holes, and the first cathode 11, the second cathode 10 and the third cathode 9 are respectively provided with threaded holes and gap holes. The mounting holes, threaded holes and gap holes cooperate with each other to achieve selective fixing of the first cathode 11, the second cathode 10 and the third cathode 9 on the first cathode mounting base 2 and the second cathode mounting base 3.

[0030] By providing mounting holes on the first cathode mounting base 2 and the second cathode mounting base 3, the cathodes can be flexibly fixed according to processing requirements. When it is necessary to adjust cathodes of different sizes, the threaded holes and clearance holes, through their matching structure with the mounting holes, allow the cathodes to be selectively fixed between the first cathode mounting base 2 and the second cathode mounting base 3. Threaded holes and clearance holes are respectively provided on the first cathode 11, the second cathode 10, and the third cathode 9. These holes, through their matching with the mounting holes on the mounting bases, enable precise installation of the cathodes.

[0031] The threaded hole and clearance hole primarily function to connect and secure the cathode to the mounting base. The threaded hole engages with fasteners to firmly fix the cathode to the mounting base, while the clearance hole adjusts the cathode's position, ensuring selective fixing based on the size and processing requirements of the casing boss. This design allows for electrolytic machining of casing bosses of different sizes without requiring cathode replacement, saving time and labor costs. The combined structure of the threaded hole and clearance hole not only improves the cathode's fixing accuracy but also allows for flexible adjustment of its operating state. During processing, the cathode's fixing state can be adjusted as needed, enabling rapid and accurate electrolytic machining of casing bosses of different sizes. This method of cathode adjustment under different processing conditions ensures high efficiency and stability in the machining process.

[0032] Reference Figure 7-10In one embodiment, a first mounting hole 16 is provided on the first cathode mounting base 2, and a second mounting hole 17 is provided on the second cathode mounting base 3; a first threaded hole 18, a first gap hole 19, and a second gap hole 20 are provided on the first cathode 11, a second threaded hole 22, a third gap hole 21, and a fourth gap hole 23 are provided on the second cathode 10, and a third threaded hole 24, a fifth gap hole 25, and a sixth gap hole 26 are provided on the third cathode 9; when the first cathode 11 is used as the main machining cathode, the fastener passes through the second mounting hole 17, the fifth gap hole 25, and the third gap hole 21 and connects to the first threaded hole 18; when the first cathode 11 is used as the main machining cathode, the fastener passes through the second mounting hole 17, the fifth gap hole 25, and the third gap hole 21 and connects to the first threaded hole 18; when the second ... When the two cathodes 10 are used as the main processing cathodes, the first cathode 11 is connected and fixed to the first cathode mounting base 2 through the first mounting hole 16 and the first threaded hole 18, and the second cathode 10 and the third cathode 9 are connected and fixed to the second cathode mounting base 3 through the second mounting hole 17, the sixth gap hole 26 and the second threaded hole 22; when the third cathode 9 is used as the main processing cathode, the first cathode 11 and the second cathode 10 are connected and fixed to the first cathode mounting base 2 through the first mounting hole 16, the second gap hole 20 and the second threaded hole 22, and the third cathode 9 is connected and fixed to the second cathode mounting base 3 through the second mounting hole 17 and the third threaded hole 24.

[0033] When the first cathode 11, the second cathode 10, and the third cathode 9 are in Figure 3 In the position shown, the first cathode 11, the second cathode 10, and the third cathode 9 are stacked together. The first cathode 11 serves as the main machining cathode. The first threaded hole 18 of the first cathode 11, the third gap hole 21 of the second cathode 10, the fifth gap hole 25 of the third cathode 9, and the second mounting hole 17 of the second cathode mounting base 3 are located on the same center line. Fastening screws are passed sequentially through the first gap hole 19, the fifth gap hole 25, and the third gap hole 21, connecting to the first threaded hole 18. Tightening the fastening screws completes the tight connection between the first cathode 11, the second cathode 10, the third cathode 9, and the second cathode mounting base 3.

[0034] When the first cathode 11, the second cathode 10, and the third cathode 9 are in Figure 4 When the position is shown, the second cathode 10 serves as the main machining cathode, the first cathode 11 is pushed to the first cathode mounting base 2, and the fastening screw passes through the first mounting hole 16 of the first cathode mounting base 2 and connects to the first threaded hole 18 of the first cathode 11, thereby fixing the first cathode 11 on the first cathode mounting base 2; the second cathode 10 and the third cathode 9 are stacked together, and the fastening screw passes through the second mounting hole 17 of the second cathode mounting base 3 and the sixth gap hole 26 of the third cathode 9 in sequence, connecting to the second threaded hole 22 of the second cathode 10, and tightening the fastening screw to achieve a tight connection between the second cathode 10, the third cathode 9 and the second cathode mounting base 3, thereby achieving the purpose of calling the boss to correspond to the cathode.

[0035] When the first cathode 11, the second cathode 10, and the third cathode 9 are in Figure 5 When the position is shown, the third cathode 9 serves as the main machining cathode. The first cathode 11 and the second cathode 10 are pushed to the first cathode mounting base 2. The fastening screw passes through the first mounting hole 16 of the first cathode mounting base 2, the second gap hole 20 of the first cathode 11, and the second threaded hole 22 of the second cathode 10, thereby fixing the first cathode 11 and the second cathode 10 on the first cathode mounting base 2. The fastening screw passes through the second mounting hole 17 of the second cathode mounting base 3 in sequence and connects to the third threaded hole 24 of the third cathode 9. By tightening the fastening screw, the third cathode 9 and the second cathode mounting base 3 are tightly connected, thereby achieving the purpose of calling the corresponding cathode of the boss.

[0036] In one embodiment, an insulating layer 12 is provided on the inner and / or outer surfaces of each cathode. The insulating layer 12 avoids the electrolytic machining portion of the corresponding housing boss to be machined, so as to form an exposed machining working surface.

[0037] An insulating layer 12 is provided on the inner and / or outer surfaces of each cathode. This design aims to reduce electrolytic corrosion in non-processed areas, concentrating electrolytic processing on the target processing area. Specifically, the insulating layer 12 ensures that the electrolyte only acts on the boss portion to be processed, without affecting other parts of the equipment, thus preventing electrolytic corrosion in non-processed areas. This design guarantees high efficiency in the electrolytic processing process and reduces unnecessary electrolyte waste.

[0038] The insulating layer 12 avoids the electrolytic machining area of ​​the casing boss, forming an exposed machining surface. This ensures that the electrolyte can only electrolyze on the machining surface, guaranteeing the accuracy and stability of the electrolytic process. Through rational design and precise control of the electrolyte flow path, the electrolytic machining effect is effectively concentrated, greatly improving the efficiency and quality of electrolytic machining. This design significantly reduces electrolyte waste in traditional electrolytic machining and minimizes damage to equipment and workpieces. Because of the insulating layer 12, the electrolyte only acts on the machining area, effectively preventing corrosion in non-machining areas and ensuring the accuracy of the final machining result. Especially during long-term, high-load electrolytic machining, it can improve the service life of the device and the machining quality.

[0039] In one embodiment, the device further includes a component base 8 for fixing the component, the component base 8 being connected to the positive terminal of a power supply.

[0040] The main function of the part base 8 is to provide stable support for the casing and electrically connect the casing to the positive terminal of the power supply, thereby achieving circuit closure for electrolytic machining. By connecting the part base 8 to the positive terminal of the power supply, it is ensured that current can flow from the positive terminal of the power supply to the machining area during electrolytic machining, and finally flow through the cathode to the negative terminal of the power supply. This design ensures the normal operation of electrolytic machining and provides a stable current flow path.

[0041] It should be understood that this embodiment uses three cathodes as an example to illustrate the structure and working principle of the composite casing boss electrolytic machining device, but it should not be regarded as a specific limitation on the number of cathodes. In other embodiments, the mounting cavity may also be provided with two or more cathodes. By nesting multiple cathodes in sequence and selectively fixing each cathode to the first cathode mounting base 2 or the second cathode mounting base 3, electrolytic machining suitable for casing bosses of different sizes can be quickly switched.

[0042] This embodiment also discloses an electrolytic machining method for composite casing bosses, including the following steps: S1, multiple hollow cathodes of different sizes are coaxially stacked in order of increasing size and installed into the mounting cavity formed by the first cathode mounting base 2 and the second cathode mounting base 3; S2. Based on the size of the machine casing boss to be processed, select a cathode whose inner hole size matches the outer size of the machine casing boss to be processed as the main processing cathode, and switch the cathode with a size smaller than the main processing cathode to the side away from the processing side and fix it. S3, connect the first cathode mounting base 2 and the second cathode mounting base 3 to the cathode base 1 to complete the cathode device assembly; S4, clamp and position the casing so that the casing boss to be processed is aligned with the main machining cathode; S5, Electrolyte is introduced into the liquid inlet 27, so that the electrolyte is directly sprayed onto the processing part of the casing boss to be processed through the electrolyte channel formed by the hollow inner cavity of multiple cathodes of different sizes, and electrolytic processing is performed. S6. After completing the machining of a casing boss of one size, the fixing states of multiple cathodes of different sizes on the first cathode mounting seat 2 and the second cathode mounting seat 3 are changed to achieve the electrolytic machining of a casing boss of another size.

[0043] By adjusting the position and fixing state of cathodes of different sizes, the machining requirements of casing bosses of different sizes can be flexibly met. When machining the smallest casing boss, the first cathode 11, the second cathode 10, and the third cathode 9 are fixed on the second cathode mounting base 3, with the first cathode 11 serving as the main machining cathode and the other cathodes playing an auxiliary role in the machining process; while when machining medium-sized casing bosses, the first cathode 11 is fixed on the first cathode mounting base 2, and the second and third cathodes 9 are jointly fixed on the second cathode mounting base 3, with the second cathode 10 serving as the main machining cathode.

[0044] For the largest casing boss, the first cathode 11 and the second cathode 10 are jointly fixed on the first cathode mounting base 2, and the third cathode 9 is fixed on the second cathode mounting base 3. The third cathode 9 serves as the main machining cathode for electrolytic machining. This design allows for flexible cathode replacement, ensuring that the main machining cathode is located on the machining side during each machining operation, while other smaller cathodes are located away from the machining area. This process significantly simplifies the complexity of replacing the entire cathode assembly required in traditional methods.

[0045] After machining a casing boss of a certain size, the cathode can be easily switched to different sizes without replacing the entire cathode assembly, allowing for the processing of casing bosses of varying sizes. This switching process not only saves time but also reduces the costs of manual operation and equipment maintenance. Through this method, the present invention achieves continuous electrolytic machining of casing bosses of multiple sizes, significantly improving processing efficiency and reducing equipment downtime and maintenance frequency.

[0046] In one embodiment, when machining casing bosses of different sizes, it is first necessary to select a suitable cathode as the main machining cathode based on the size of the casing boss to be machined. When machining the smallest casing boss, the first cathode 11, the second cathode 10, and the third cathode 9 are all fixed on the second cathode mounting base 3, with the first cathode 11 serving as the main machining cathode. At this time, the working surface of the first cathode 11 is opposite to the machining surface of the casing boss, enabling efficient electrolytic machining of the boss.

[0047] When machining the intermediate-sized casing boss, the first cathode 11 is fixed to the first cathode mounting base 2, and the second cathode 10 and the third cathode 9 are jointly fixed to the second cathode mounting base 3. The second cathode 10 serves as the main machining cathode. In this state, the positional relationship between the first cathode 11, the second cathode 10, and the third cathode 9 is adjusted, thereby enabling the second cathode 10 to better perform electrolytic machining on the intermediate-sized area of ​​the casing boss to be machined.

[0048] When machining the largest casing boss, the first cathode 11 and the second cathode 10 are both fixed to the first cathode mounting base 2, and the third cathode 9 is fixed to the second cathode mounting base 3, with the third cathode 9 serving as the main machining cathode. At this time, the first and second cathodes 10 take on an auxiliary role, providing a stable electrolytic environment to ensure that the third cathode 9 can accurately machine the largest casing boss.

[0049] This design allows for the sequential processing of casing bosses of different sizes throughout the machining process without the need to replace the entire cathode assembly. Each time, only the position and fixing method of the cathodes need to be adjusted, selecting the cathode that matches the size of the casing boss to be processed as the primary cathode, while the other cathodes are moved to positions away from the processing side. This not only improves the flexibility of the equipment but also reduces the time and operating costs for operators changing cathodes.

[0050] In one embodiment, a sequential machining method is used when machining multiple casing bosses of different sizes. First, electrolytic machining is performed sequentially according to the size of the casing bosses, from smallest to largest. After machining each size of casing boss, the fixing state of the cathode is adjusted to accommodate the machining requirements of the next size. Specifically, between machining two adjacent sizes of casing bosses, only the fixing states of multiple cathodes of different sizes on the first cathode mounting base 2 and the second cathode mounting base 3 need to be changed, without replacing the cathode assembly.

[0051] The advantage of this method is that it eliminates the need to replace the entire cathode assembly. By adjusting the fixing state of the cathodes, it can quickly adapt to the electrolytic machining requirements of casing bosses of different sizes. Each time a different size casing boss is machined, only the appropriate cathode is selected as the main machining cathode according to the size of the boss to be machined, and the remaining cathodes are moved to positions away from the machining side by adjusting their fixing states. This not only reduces equipment downtime and cathode assembly replacement time but also improves production efficiency and avoids errors and unnecessary losses caused by changing cathodes during manual operation. Another advantage of this method is the continuity of the machining process. After completing the machining of a casing boss of one size, the fixing state of the cathodes can be adjusted immediately to proceed to the machining of the next size casing boss, without waiting for lengthy equipment adjustments or cathode replacements. This continuous machining method greatly improves production efficiency and saves production time.

[0052] In one embodiment, during electrolytic machining, a main machining cathode that matches the size of the machine casing boss to be machined is fitted around the outer periphery of the machine casing boss to form a corresponding annular machining gap between the main machining cathode and the machine casing boss.

[0053] The outer circumference of the main machining cathode matches the outer circumference of the casing boss to be machined. This design allows the main machining cathode to fit snugly around the casing boss, forming an annular machining gap. During machining, the electrolyte is sprayed into the machining area through electrolyte channels, precisely targeting the outer shape of the casing boss. This annular machining gap design ensures that the electrolyte evenly covers the machining area, thereby improving machining accuracy.

[0054] Reference Figure 11 In a specific implementation, the electrolytic machining method for composite casing bosses includes the following steps: (1) The first cathode 11, the second cathode 10, and the third cathode 9 are stacked together and placed in the inner cavity of the second cathode mounting base 3, so that the first threaded hole 18 of the first cathode 11, the third gap hole 21 of the second cathode 10, the fifth gap hole 25 of the third cathode 9, and the second mounting hole 17 of the second cathode mounting base 3 are on the same center line. The fastening screws are passed through the first gap hole 19, the fifth gap hole 25, and the third gap hole 21 in sequence and connected to the first threaded hole 18. The fastening screws are tightened to complete the tight connection between the first cathode 11, the second cathode 10, the third cathode 9 and the second cathode mounting base 3. At this time, the first boss 13 is processed.

[0055] (2) The first cathode mounting base 2 and the second cathode mounting base 3 are connected by screws. The first cathode mounting base 2 is connected to the cathode base 1 by screws. The cathode base 1 is connected to the spindle of the machine tool side wall to complete the assembly of the cathode device.

[0056] (3) Screw the center stud 6 into the threaded hole in the center of the part base 8, place the machine casing on the part base 8, press the cover plate 4 on the top of the machine casing, tighten the clamping nut 5, and complete the part installation and positioning; install the part base 8 on the rotating shaft of the machine tool to complete the assembly of the fixture assembly.

[0057] (4) By rotating the machine tool's rotating shaft, the fixture assembly is rotated, thereby aligning the first boss 13 on the casing with the cathode. The electrolyte is connected to the liquid inlet 27 of the cathode base 1. The process parameters are set, and the first boss 13 is processed.

[0058] (5) After all the first bosses 13 have been processed, the second bosses 14 are processed. The first cathode 11 is pushed to the first cathode mounting base 2, and the fastening screw passes through the first mounting hole 16 of the first cathode mounting base 2 and connects to the first threaded hole 18 of the first cathode 11, thereby fixing the first cathode 11 on the first cathode mounting base 2; the second cathode 10 and the third cathode 9 are stacked together, and the fastening screw passes through the second mounting hole 17 of the second cathode mounting base 3 and the sixth gap hole 26 of the third cathode 9 in sequence, connecting to the second threaded hole 22 of the second cathode 10, and tightening the fastening screw to achieve a tight connection between the second cathode 10, the third cathode 9 and the second cathode mounting base 3, thereby completing the cathode replacement; the electrolyte is turned on, the process parameters are set, and the processing of the second bosses 14 begins.

[0059] (6) After all the second bosses 14 have been machined, the machining of the third boss 15 begins. The first cathode 11 and the second cathode 10 are pushed to the first cathode mounting base 2. The fastening screws pass through the first mounting hole 16 of the first cathode mounting base 2, the second gap hole 20 of the first cathode 11, and the second threaded hole 22 of the second cathode 10, thereby fixing the first cathode 11 and the second cathode 10 on the first cathode mounting base 2. The fastening screws pass through the second mounting hole 17 of the second cathode mounting base 3 and connect to the third threaded hole 24 of the third cathode 9. The fastening screws are tightened to achieve a tight connection between the third cathode 9 and the second cathode mounting base 3, thereby completing the cathode replacement. The electrolyte is turned on, the process parameters are set, and the machining of the third boss 15 begins. At this point, the electrolytic machining of all bosses is completed.

[0060] The above description is merely a preferred embodiment of this application and is not intended to limit this application. Various modifications and variations can be made to this application by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this application should be included within the protection scope of this application.

Claims

1. A composite casing boss electrolytic machining apparatus, characterized in that: It includes a cathode base (1), a first cathode mounting base (2), a second cathode mounting base (3), and multiple cathodes of different sizes. The first cathode mounting base (2) and the second cathode mounting base (3) are connected along the processing direction to form an mounting cavity, and multiple cathodes of different sizes are provided in the mounting cavity. Multiple cathodes of different sizes are hollow structures and are coaxially stacked in order of increasing size. The hollow cavities of the multiple cathodes of different sizes are used to process casing bosses of different sizes. Each cathode can be selectively fixed on the first cathode mounting base (2) or the second cathode mounting base (3) so that the cathode corresponding to the size of the machine casing boss to be processed is located on the processing side and serves as the main processing cathode, while the cathode with a size smaller than the main processing cathode is switched to the side away from the processing side. The cathode base (1) is provided with an inlet (27) for the electrolyte to enter. The hollow cavities of multiple cathodes of different sizes together form an electrolyte channel that communicates with the inlet (27). The electrolyte channel is used to guide the electrolyte to the processing part of the casing boss to be processed.

2. The composite casing boss electrolytic machining apparatus according to claim 1, characterized in that: Multiple cathodes of different sizes include a first cathode (11), a second cathode (10), and a third cathode (9), with the inner diameters of the first cathode (11), the second cathode (10), and the third cathode (9) increasing sequentially. When the first cathode (11) is used as the main processing cathode, the first cathode (11), the second cathode (10) and the third cathode (9) are fixed together on the second cathode mounting base (3); When the second cathode (10) is used as the main processing cathode, the first cathode (11) is fixed on the first cathode mounting base (2), and the second cathode (10) and the third cathode (9) are fixed together on the second cathode mounting base (3); When the third cathode (9) is used as the main processing cathode, the first cathode (11) and the second cathode (10) are fixed together on the first cathode mounting base (2), and the third cathode (9) is fixed on the second cathode mounting base (3).

3. The composite casing boss electrolytic machining apparatus according to claim 2, characterized in that: The first cathode mounting base (2) and the second cathode mounting base (3) are respectively provided with mounting holes, and the first cathode (11), the second cathode (10) and the third cathode (9) are respectively provided with threaded holes and gap holes. When different cathodes are used as the main processing cathodes, the fastener passes through the mounting holes on the corresponding cathode mounting base and the gap holes on the corresponding cathode, and then connects with the threaded holes on the corresponding cathode, so as to achieve selective fixing of the first cathode (11), the second cathode (10) and the third cathode (9) on the first cathode mounting base (2) and the second cathode mounting base (3).

4. The composite casing boss electrolytic machining apparatus according to claim 3, characterized in that: The first cathode mounting base (2) is provided with a first mounting hole (16), and the second cathode mounting base (3) is provided with a second mounting hole (17); The first cathode (11) is provided with a first threaded hole (18), a first gap hole (19) and a second gap hole (20), the second cathode (10) is provided with a second threaded hole (22), a third gap hole (21) and a fourth gap hole (23), and the third cathode (9) is provided with a third threaded hole (24), a fifth gap hole (25) and a sixth gap hole (26); When the first cathode (11) is used as the main machining cathode, the fastener passes through the second mounting hole (17), the fifth gap hole (25) and the third gap hole (21) and connects to the first threaded hole (18) to fix the first cathode (11), the second cathode (10) and the third cathode (9) on the second cathode mounting base (3); When the second cathode (10) is used as the main machining cathode, the first cathode (11) is connected to the first threaded hole (18) through the first mounting hole (16) and fixed on the first cathode mounting base (2), and the second cathode (10) and the third cathode (9) are connected to the second threaded hole (22) through the second mounting hole (17) and the sixth gap hole (26) and fixed on the second cathode mounting base (3); When the third cathode (9) is used as the main machining cathode, the fastener passes through the first mounting hole (16) and the second gap hole (20) and connects to the second threaded hole (22) to fix the first cathode (11) and the second cathode (10) on the first cathode mounting base (2). The third cathode (9) is connected to the third threaded hole (24) through the second mounting hole (17) and fixed on the second cathode mounting base (3).

5. The composite casing boss electrolytic machining apparatus according to claim 1, characterized in that: An insulating layer (12) is provided on the inner and / or outer surfaces of each cathode. The insulating layer (12) avoids the electrolytic machining part of the corresponding machine casing boss to be machined, so as to form an exposed machining working surface.

6. The composite casing boss electrolytic machining apparatus according to claim 1, characterized in that: It also includes a component base (8) for fixing the component, which is connected to the positive terminal of the power supply.

7. A method for electrolytic machining of composite casing bosses, characterized in that, The composite casing boss electrolytic machining apparatus according to any one of claims 1 to 6 includes the following steps: S1, multiple hollow cathodes of different sizes are coaxially stacked in order of increasing size and installed into the mounting cavity formed by the first cathode mounting base (2) and the second cathode mounting base (3); S2. Based on the size of the machine casing boss to be processed, select a cathode whose inner hole size matches the outer size of the machine casing boss to be processed as the main processing cathode, and switch the cathode with a size smaller than the main processing cathode to the side away from the processing side and fix it. S3, connect the first cathode mounting base (2) and the second cathode mounting base (3) to the cathode base (1) to complete the cathode device assembly; S4, clamp and position the casing (7) so that the casing boss to be processed is aligned with the main processing cathode; S5, Electrolyte is introduced into the inlet (27) so that the electrolyte is directly sprayed into the processing part of the casing boss to be processed through the electrolyte channel formed by the hollow inner cavity of multiple cathodes of different sizes, and electrolytic processing is performed. S6. After completing the machining of a casing boss of one size, the fixing states of multiple cathodes of different sizes on the first cathode mounting base (2) and the second cathode mounting base (3) are changed to realize the electrolytic machining of a casing boss of another size.

8. The method for electrolytic machining of composite casing bosses according to claim 7, characterized in that: Multiple cathodes include a first cathode (11), a second cathode (10), and a third cathode (9). When machining the smallest size casing boss, the first cathode (11), the second cathode (10), and the third cathode (9) are fixed together on the second cathode mounting base (3), and the first cathode (11) is used as the main machining cathode for machining. When machining the casing boss of the intermediate size, the first cathode (11) is fixed on the first cathode mounting base (2), and the second cathode (10) and the third cathode (9) are fixed together on the second cathode mounting base (3), with the second cathode (10) serving as the main machining cathode for machining; When machining the largest size casing boss, the first cathode (11) and the second cathode (10) are fixed together on the first cathode mounting base (2), and the third cathode (9) is fixed on the second cathode mounting base (3). The third cathode (9) is used as the main machining cathode for machining.

9. The method for electrolytic machining of composite casing bosses according to claim 7, characterized in that: When machining multiple casing bosses of different sizes, electrolytic machining is performed sequentially according to the size of the casing bosses from small to large or from large to small. Between machining of two adjacent casing bosses of different sizes, the machining is switched by changing the fixed state of multiple cathodes of different sizes on the first cathode mounting base (2) and the second cathode mounting base (3).

10. The method for electrolytic machining of composite casing bosses according to claim 7, characterized in that: During electrolytic machining, the main machining cathode, which is compatible with the size of the machine casing boss to be machined, is fitted around the outer periphery of the machine casing boss to form a corresponding annular machining gap between the main machining cathode and the machine casing boss.

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