Complexly shaped gradually changing body tube bore electrolytic processing short circuit prevention cathode body structure

Abstract

The application relates to a complex special-shaped gradually-changing barrel inner bore electrolytic processing short-circuit-preventing cathode body structure, which comprises a cathode working tooth, insulating glass, a rear guide and a right-handed flow guide groove spirally extending along the cathode body axis, the insulating glass is arranged on the outer periphery of the cathode working tooth, and the rear guide is arranged at the rear end of the cathode working tooth; the structure further comprises an insulating glass flow guide section and an annular flow distribution groove. The insulating glass flow guide section is additionally arranged between the working tooth tail end and the rear guide, a continuous insulating flow guide section is formed by the insulating glass flow guide section and the extended insulating glass, the traditional cross intersection gap is axially rearwardly arranged, the conductive area at the gap is effectively reduced, the risk of tip puncture and discharge ablation at the working tooth tail end is reduced from the source, meanwhile, the insulating glass flow guide section is matched with the spiral structure of the working tooth, the rear guide and the flow guide groove, the smoothness of the electrolyte flowing in the inner flow channel is ensured, and local disorder caused by flow field mutation is avoided.

Description

Technical Field

[0001] This invention relates to the field of barrel processing technology, specifically to a short-circuit-proof cathode structure for electrolytic processing of the inner bore of a complex irregularly shaped, gradually changing barrel. Background Technology

[0002] With the continuous improvement of the requirements for the service of weapons and equipment, the internal structure of small-caliber barrels is gradually developing towards a gradual and complex shape, which puts forward more stringent requirements for their machining accuracy and surface quality. Electrolytic machining has become the mainstream machining process for complex and gradually changing barrel internal structures due to its advantages such as high machining efficiency, no cutting force, and no tool cathode wear.

[0003] However, existing cathode bodies for electrolytic machining have significant structural design flaws: when the electrolyte flows along the right-hand spiral guide groove within the cathode body's flow channel, it easily forms uneven electrolyte pooling and accumulation at the end of the working teeth; simultaneously, the cross-shaped gap formed at the junction of the working teeth and the insulating glass has a large conductive area, which easily triggers high-frequency tip discharge, ultimately leading to ablation and damage to the cathode body. These problems not only significantly reduce the service life of the cathode body but also result in low yield rates, high production costs, and low production efficiency in tube machining, severely restricting the stable mass production of complex, irregularly shaped, gradually changing tube bores. Summary of the Invention

[0004] To address the shortcomings of existing technologies, this invention provides a short-circuit-proof cathode body structure for electrolytic machining of the inner bore of a complex irregularly shaped, tapered tube, thus solving the problems mentioned in the background technology.

[0005] To achieve the above objectives, the present invention is implemented through the following technical solution: a short-circuit-proof cathode body structure for electrolytic machining of the inner bore of a complex irregularly shaped tapered tube, comprising: a cathode working tooth, an insulating glass, a rear guide, and a right-hand spiral guide groove extending along the axial direction of the cathode body; the insulating glass is disposed on the outer periphery of the cathode working tooth, the rear guide is disposed at the rear end of the cathode working tooth, and the structure also includes an insulating glass guide section and an annular diversion groove. The insulating glass guide section has an annular sawtooth structure and is coaxially arranged between the end of the cathode working tooth and the front end of the rear guide. It is adapted to the spiral groove structure of the end of the cathode working tooth, the rear guide, and the guide groove to achieve a smooth transition of the electrolyte in the flow channel of the cathode body. The insulating glass guide section is adjacent to and continuously transitions with the insulating glass that extends along the spiral direction, forming a continuous insulating guide section covering the end of the working tooth. This axially moves the cross intersection gap at the intersection of the working tooth end and the insulating glass in the traditional cathode body to the rear, reducing the probability of sharp point puncture at the end of the working tooth. The annular diversion groove is coaxially opened at the front end of the rear guide and close to the end of the cathode working tooth. It is used to preferentially guide the electrolyte flowing out of the end of the working tooth into the groove for convergence and diversion under the drive of the electrolyte flow potential energy, thereby eliminating the accumulation of electrolyte at the end of the working tooth and working together with the insulating glass guide section to solve the problem of high frequency ablation of the cathode body.

[0006] Preferably, the axial length of the insulating glass guide section is 2-4 mm, with an optimal value of 3 mm.

[0007] Preferably, the diameter of the annular diversion groove is 24.7 mm, the groove width is 3-4 mm, and the optimal value is 3.5 mm; the axial distance between the right end face of the annular diversion groove and the left end face of the insulating glass guide section is 9-11 mm, and the optimal value is 10 mm.

[0008] Preferably, the helix angle of the sawtooth structure of the insulating glass guide section is exactly the same as the helix angle of the right-handed guide groove, and the top of the sawtooth smoothly transitions to the bottom of the guide groove, and the root of the sawtooth smoothly transitions to the wall of the guide groove.

[0009] Preferably, the length of the extended section of the insulating glass matches the axial length of the insulating glass guide section, and the mating surface of the two is inclined and seamlessly fitted, forming a continuous insulating barrier without breaks.

[0010] Preferably, the cross-section of the annular diversion channel is arc-shaped, the radius of the transition fillet between the bottom of the channel and the wall of the channel is 0.3-0.5mm, and the edge of the channel opening is chamfered with a chamfer radius of 0.2mm.

[0011] Preferably, the end face of the cathode working tooth is a circular arc transition end face with a radius of 0.5-1mm, and the circular arc transition end face is smoothly connected to the front face of the insulating glass guide section without any steps.

[0012] Preferably, the right-handed guide groove on the rear guide has the same helix angle and the same groove width as the right-handed guide groove on the cathode working tooth, and the coaxiality of the two is ≤0.01mm.

[0013] Preferably, after the electrolyte flows along the right-handed guide channel to the end of the cathode working tooth, it is guided by the insulating glass guide section. 30%-40% of the electrolyte enters the annular diversion channel to complete the convergence, diversion and buffering. The remaining electrolyte merges with the electrolyte flowing out of the annular diversion channel and is discharged in an orderly manner along the rear-guided guide channel.

[0014] Preferably, when using this cathode body to process the inner bore of a complex, irregularly shaped, gradually changing tube, the cathode body has an ablation resistance processing life of ≥30 tubes / piece, the surface roughness Ra of the inner bore of the tube after processing is ≤0.4μm, and the dimensional accuracy of the cathode and cathode wires is ≤0.02mm.

[0015] This invention provides a short-circuit-resistant cathode body structure for electrolytic machining of the inner bore of complex irregularly shaped, tapered tubes, which has the following beneficial effects: 1. By adding an insulating glass guide section between the end of the working tooth and the rear guide, and forming a continuous insulating guide section with the extended insulating glass, the traditional cross-shaped gap is axially moved to the rear, effectively reducing the conductive area at the gap and reducing the risk of sharp-point puncture and discharge ablation at the end of the working tooth from the source. At the same time, the insulating glass guide section is compatible with the spiral structure of the working tooth, the rear guide, and the guide groove, ensuring the smoothness of the electrolyte flow in the inner channel and avoiding local turbulence caused by sudden changes in the flow field.

[0016] 2. By setting an annular diversion groove at the front end of the rear guide near the end of the working tooth, the electrolyte itself can be used to guide the electrolyte flowing out of the end of the working tooth to the groove for convergence, diversion and buffering. This completely eliminates the uneven accumulation of electrolyte at the end of the working tooth and improves the electrolyte renewal and discharge conditions in the rear section of the processing area.

[0017] 3. The synergistic effect of the insulating glass guide section and the annular flow divider solves the high-frequency ablation problem of traditional cathode bodies from both the electric field and flow field dimensions, significantly improving the working stability and service life of the cathode body and reducing the overall cost of barrel processing. At the same time, this structural design does not change the original forming accuracy of the barrel bore and can also effectively improve the problem of stray corrosion on the bore surface, improve the surface quality of the processed material, and fully meet the needs of mass industrial production of complex irregularly shaped and gradually changing barrel bores. Attached Figure Description

[0018] Figure 1 This is an overall schematic diagram of the cathode body structure of the present invention; Figure 2 A schematic diagram of the overall structure of a traditional cathode body; Figure 3 This is a schematic diagram of the annular flow divider structure of the cathode body of the present invention; Figure 4 This is a schematic diagram of the insulating glass current-conducting section structure of the cathode body of the present invention; Figure 5-1 This is a simulation analysis diagram of the radial distribution of the etching current density at the end of the working tooth under the multi-physics field coupling effect when the length L of the insulating glass current-conducting section of the cathode body of the present invention is 1 mm. Figure 5-2 This is a simulation analysis diagram of the radial distribution of the etching current density at the end of the working tooth under the multi-physics field coupling effect when the length L of the insulating glass current-conducting section of the cathode body of the present invention is 3mm. Figure 5-3 This is a simulation analysis diagram of the radial distribution of the etching current density at the end of the working tooth under the coupling effect of multiple physical fields when the length L of the insulating glass current-conducting section of the cathode body of the present invention is 5 mm. Figure 6-1 This is a simulation analysis diagram of the overall streamline of the electrolytic processing electrolyte moving through the cathode body when the width W of the annular flow channel of the cathode body is 2.5 mm. Figure 6-2 This is a simulation analysis diagram of the overall streamline of the electrolytic processing electrolyte moving through the cathode body when the width W of the annular flow channel of the cathode body is 3.5 mm. Figure 6-3 This is a simulation analysis diagram of the overall streamline of the electrolytic processing electrolyte moving through the cathode body when the width W of the annular flow channel of the cathode body is 4.5 mm. Figure 6-4 This is a simulation analysis diagram of the overall streamline of the electrolytic processing electrolyte moving through the cathode body when the axial distance D of the annular diversion groove of the cathode body is 8 mm. Figure 6-5 This is a simulation analysis diagram of the overall streamline of the electrolytic processing electrolyte moving through the cathode body when the axial distance D of the annular diversion groove of the cathode body is 10 mm. Figure 6-6 This is a simulation analysis diagram of the overall streamline of the electrolytic processing electrolyte moving through the cathode body when the axial distance D of the annular diversion groove of the cathode body is 12 mm. Figure 7-1 This is a simulation analysis diagram of the overall streamline of a traditional cathode body during electrolytic machining, showing the movement of electrolyte within the cathode body's internal channels. Figure 7-2 This is a simulation analysis diagram of the overall streamline of the cathode body during electrolytic machining of the present invention, showing the movement of the electrolyte in the cathode body's internal flow channel. Figure 8 Simulation cloud diagrams of electrolyte flow velocity distribution at the end section of the working tooth for conventional cathode bodies and cathode bodies of the present invention during electrolytic machining; Figure 9 Simulation cloud diagram of electrolyte flow velocity distribution during electrolytic machining of the cathode body in the middle section of the annular flow divider of the present invention; Figure 10-1 The simulation analysis diagram shows the radial distribution of the erosion current density on the surface of the anode workpiece corresponding to the end section of the working tooth of the traditional cathode under the coupling effect of multiple physical fields in electrolytic machining. Figure 10-2 This is a simulation analysis diagram of the radial distribution of the erosion current density on the surface of the anode workpiece corresponding to the end section of the working tooth of the cathode body in this invention under the coupling effect of multiple physical fields in electrolytic machining. Figure 10-3 The simulation analysis diagram shows the radial distribution of the erosion current density at the end cross section of the working tooth of a traditional cathode under the coupling effect of multiple physics fields in electrolytic machining. Figure 10-4This is a simulation analysis diagram of the radial distribution of the etching current density on the surface of the anode workpiece corresponding to the end section of the working tooth of the cathode body in this invention under the coupling effect of multiple physical fields in electrolytic machining.

[0019] Reference numerals in the attached diagram: 1. Cathode working tooth; 2. Insulating glass; 3. Insulating glass guide section; 4. Rear guide; 5. Annular diversion groove; 6. Guide groove. Detailed Implementation

[0020] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0021] like Figures 1 to 10-4 As shown, the present invention provides a technical solution for a short-circuit-proof cathode body structure structure produced by electrolytic machining of the inner bore of a complex irregularly shaped, gradually changing tube.

[0022] This embodiment provides a short-circuit-prevention cathode structure for electrolytic machining of complex, irregularly shaped, tapered tube inner bores. It aims to solve the problems of uneven electrolyte flow and accumulation at the end of the working teeth during traditional cathode machining, as well as high-frequency tip discharge and cathode ablation caused by the cross-shaped gap at the intersection of the working teeth and the insulating glass. The overall structure of this invention is as follows: Figure 1 As shown, it includes a cathode working tooth 1, insulating glass 2, insulating glass guide section 3, rear guide 4, an annular diversion groove 5, and a right-handed guide groove 6 extending spirally along the cathode body axis; wherein, the insulating glass 2 is disposed on the outer periphery of the cathode working tooth 1, and the rear guide 4 is disposed at the rear end of the cathode working tooth 1. Figure 2 Compared with the traditional cathode structure shown, the present invention innovatively adds an insulating glass guide section 3 and an annular diversion groove 5, forming a composite short-circuit protection design of "the gap cross where the working tooth ends meet with the insulating glass is placed behind and the annular current-diverting groove is introduced behind", which solves the high-frequency ablation problem of the traditional cathode body from the two dimensions of electric field and flow field.

[0023] like Figure 4 As shown, the insulating glass guide section 3 has an annular sawtooth structure and is coaxially disposed between the end of the cathode working tooth 1 and the front end of the rear guide 4. The helix angle of its sawtooth structure is completely consistent with the helix angle of the right-handed guide groove 6, and the tooth tip of the sawtooth smoothly transitions to the bottom of the guide groove 6, and the tooth root of the sawtooth smoothly transitions to the wall of the guide groove 6, realizing a smooth transition of the electrolyte in the cathode body without abrupt changes.

[0024] Simultaneously, the insulating glass 2 extends and lengthens along the spiral direction, with the length of the extended section matching the axial length of the insulating glass guide section 3. The mating surfaces of the two are beveled and seamlessly fitted, forming a continuous insulating guide section without breaks, consisting of "insulating glass 2 + insulating glass guide section 3". This design moves the cross-shaped intersection gap at the junction of the working tooth end and the insulating glass in the traditional cathode body axially backward, effectively reducing the conductive area at the gap and decreasing the probability of tip penetration and discharge ablation at the working tooth end from the source.

[0025] like Figure 3 As shown, the annular diversion groove 5 is coaxially located at the front end of the rear guide 4 and close to the end of the cathode working tooth 1. Its cross-section is arc-shaped, with a transition radius of 0.3-0.5 mm between the groove bottom and the groove wall. The groove opening edge is chamfered with a chamfer radius of 0.2 mm to prevent the generation of new electric field concentration points at the groove edge. Driven by the potential energy of the electrolyte flow, the electrolyte flowing out of the working tooth end will preferentially flow into the annular diversion groove 5 for convergence, diversion, and buffering, completely eliminating the uneven accumulation of electrolyte at the working tooth end, and forming a synergistic anti-ablation effect with the insulating glass guide section 3.

[0026] To further improve flow field stability and short-circuit protection, the present invention optimizes the supporting structure: the end face of the cathode working tooth 1 is a circular arc transition face with a radius of 0.5-1mm, and the circular arc transition face smoothly connects with the front face of the insulating glass guide section 3 without steps, avoiding local turbulence caused by sudden changes in the flow field; the right-handed guide groove on the rear guide 4 has the same helix angle and groove width as the right-handed guide groove 6 on the cathode working tooth 1, and the coaxiality of the two is ≤0.01mm, ensuring the continuous and stable flow of electrolyte along the entire cathode body channel.

[0027] To determine the optimal parameters of the insulating glass flow guide section and the annular flow divider, this invention conducted multiple sets of comparative embodiments for verification through numerical simulation of single flow field and multi-physics field (electric-current-temperature) coupling.

[0028] Example 1: Optimization of axial length of insulating glass guide section: In this set of embodiments, the axial length L of the insulating glass current-conducting section is taken as 1mm, 3mm, and 5mm, respectively, to characterize the axial rearward placement of the discharge tip of the cross-shaped gap. The distribution characteristics of the radial erosion current density at the end of the working tooth under different lengths are as follows: Figure 5-1 , Figure 5-2 , Figure 5-3 As shown: When L=1mm (e.g.) Figure 5-1 As shown in the figure, the current density at the end of the working tooth fluctuates too much and the local peak value is too high. There are obvious upward spikes at the beginning and end of the interval, indicating a high risk of sharp discharge. When L=3mm (e.g.) Figure 5-2 As shown in the figure, the current density distribution curve is generally flat and stable, the peak value is significantly reduced, the fluctuations along the path converge, no obvious sudden spikes are seen, and the electric field uniformity is optimal. When L=5mm (e.g.) Figure 5-3 As shown in the figure, the average current density is close to L=3mm, but the fluctuations at the beginning and end of the interval and the local peaks are significantly increased, and the uniformity of distribution decreases.

[0029] A comprehensive comparison shows that the optimal axial length of the insulating glass guide section is 3mm, with a range of 2-4mm.

[0030] Example 2: Optimization of the width of the annular flow divider: In this set of embodiments, the width W of the annular diversion tank is 2.5mm, 3.5mm, and 4.5mm, respectively. The flow characteristics of the electrolyte under different tank widths are as follows: Figure 6-1 , Figure 6-2 , Figure 6-3 As shown: When W=2.5mm (e.g.) Figure 6-1 As shown in the figure, the flow capacity of the diversion tank is limited, the flow rate of electrolyte entering the diversion tank is insufficient, there are many crossovers of streamlines in the transition zone, and the local backflow and stagnation phenomena are obvious. When W=3.5mm (e.g.) Figure 6-2 As shown in the figure, the electrolyte flows into the distribution tank more fully, the distribution and buffering effects are significant, the flow lines in the transition zone tend to be smoother, the reflux and retention range are greatly reduced, and the discharge is continuous and stable. When W=4.5mm (e.g.) Figure 6-3 As shown in the figure, an excessively large diversion range leads to an increase in the residence time of the electrolyte in the tank, an increase in local low velocity and stagnation tendency, a dispersion of the mainstream discharge momentum, and a rebound in the disturbance of the transition zone.

[0031] A comprehensive comparison shows that the optimal width of the annular diversion channel is 3.5 mm, with a range of 3-4 mm.

[0032] Example 3: Optimization of the axial position of the annular diversion channel: In this set of embodiments, the axial position of the annular diversion channel is characterized by "the axial distance D between the right end face of the annular diversion channel 5 and the left end face of the insulating glass guide section 3". D is taken as 8mm, 10mm, and 12mm respectively. The flow field characteristics at different axial positions are as follows: Figure 6-4 , Figure 6-5 , Figure 6-6 As shown: When D=8mm (e.g.) Figure 6-4 As shown in the figure, the diversion position is too far forward, the disturbance in the transition zone is enhanced, and local backflow and stagnation are more likely to occur; When D=10mm (e.g.) Figure 6-5As shown in the figure, the diversion position is moderate, the streamline of the transition zone is more continuous, the reflux and retention range is minimal, and the electrolyte discharge is most stable; When D=12mm (e.g.) Figure 6-6 As shown in the figure, the flow splitting position is too far back, which weakens the improvement effect on the flow field at the end of the working tooth, and the disturbance and streamline crossing in the front end region increase, increasing the tendency for insufficient electrolyte renewal.

[0033] Based on comprehensive comparison, the optimal axial distance of the annular diversion channel is 10mm, with a range of 9-11mm; combined with the channel width optimization results, the diameter of the annular diversion channel is determined to be 24.7mm.

[0034] Overall performance simulation verification: Electrolyte flow characteristics verification: To verify the overall improvement effect of the cathode of this invention on the electrolyte flow field, numerical simulations of electrolyte flow characteristics were conducted on both the conventional cathode and the cathode of this invention. The results are as follows: Figure 7-1 , Figure 7-2 , Figure 8 , Figure 9 As shown: Overall streamline comparison: Figure 7-1 The overall flow lines of the electrolyte in a traditional cathode body show that there are many intersections and disordered trajectories in the latter part of the processing area, with obvious signs of local backflow, vortex and stagnation. Figure 7-2 The overall streamline of the electrolyte in the cathode body of this invention shows that the crossover of the streamlines is significantly reduced, the trajectory is smoother, the reflux and vortex range is greatly reduced, and the electrolyte can first converge, divide and buffer in the annular diversion tank, and then be discharged in an orderly manner along the rear guide channel.

[0035] Velocity distribution at the tip of the working tooth: Figure 8 The image shows the electrolyte flow velocity distribution cloud map at the end section of the working tooth of the conventional cathode and the cathode of the present invention. As can be seen from the comparison, the conventional cathode has obvious local voids and low-velocity areas, while the flow velocity distribution of the cathode of the present invention is more continuous and more uniform in the circumference. The local voids and low-velocity areas are effectively weakened or eliminated, and the tendency of electrolyte retention and accumulation is greatly reduced.

[0036] Velocity distribution inside the annular flow divider: Figure 9 The image shows the electrolyte flow velocity distribution cloud map of the cathode body in the middle section of the annular distribution tank. It can be seen that the cross section is mainly composed of medium and low speeds with local high speeds, indicating that the electrolyte achieves multi-point inflow, circumferential diffusion and redistribution in the annular distribution tank, giving full play to the functions of convergence, diversion and pressure relief and buffering transition.

[0037] Verification of multi-physics coupled erosion current density: To verify the improvement effect of the cathode of this invention on the electric field distribution, numerical simulations of the erosion current density under multiphysics coupling were conducted on both a conventional cathode and the cathode of this invention. The results are as follows: Figure 10-1 , Figure 10-2 , Figure 10-3 , Figure 10-4 As shown: Current density distribution on the surface of the anode workpiece: Figure 10-1 The image shows the current density distribution cloud map of the etch current density distribution on the surface of the anode workpiece corresponding to the cross section at the end of the working tooth of the traditional cathode. It can be seen that there are obvious current density spikes and uneven distribution. Figure 10-2 The image shows the current density distribution cloud map at the corresponding position of the cathode body in this invention. It can be seen that the uniformity of the current density is significantly improved and the cusp features have basically disappeared.

[0038] Current density distribution at the end of the cathode working tooth: Figure 10-3 The radial distribution curve of the etch current density at the end cross section of the working tooth of a conventional cathode is shown. It can be seen that the curve fluctuates violently and has multiple obvious peaks. Figure 10-4 The curves show the distribution at the corresponding positions of the cathode body in this invention. It can be seen that the curves are generally flat, with a significant reduction in local peak values ​​and convergence of fluctuations along the path, indicating that the concentration trend of electric field and current density at the end has been effectively suppressed.

[0039] Electrolyte flow path and actual processing effect: During electrolytic machining, the electrolyte flow path is as follows: the electrolyte flows along the right-handed guide channel 6 to the end of the cathode working tooth 1, then is guided by the insulating glass guide section 3. 30%-40% of the electrolyte enters the annular diversion channel 5 to complete the confluence, diversion, and buffering. The remaining electrolyte merges with the electrolyte flowing out of the annular diversion channel 5 and is then discharged orderly along the guide channel of the rear guide 4. This flow method effectively improves the electrolyte renewal and discharge conditions in the rear section of the machining area, fundamentally avoiding uneven accumulation of electrolyte at the end of the working tooth.

[0040] Actual production and processing verification results show that, under the same equipment and process environment, when using the cathode body designed in this invention to process the inner bore of complex irregularly shaped tapered tubes, the ablation resistance processing life of the cathode body is ≥30 tubes / piece, the surface roughness Ra of the inner bore of the processed tube is ≤0.4μm, the dimensional accuracy of the cathode and cathode wires is ≤0.02mm, the stray corrosion on the surface of the cathode wire in the inner bore is significantly improved, and the production cost is significantly reduced, which fully meets the needs of mass industrial production of complex irregularly shaped tapered tube inner bores.

[0041] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A short-circuit-resistant cathode body structure for electrolytic machining of the inner bore of a complex, irregularly shaped, gradient-shaped tube, characterized in that: include: It includes a cathode working tooth (1), an insulating glass (2), a rear guide (4) and a right-handed guide groove (6) extending spirally along the cathode body axis. The insulating glass (2) is disposed on the outer periphery of the cathode working tooth (1), and the rear guide (4) is disposed at the rear end of the cathode working tooth (1). The feature is that it also includes an insulating glass guide section (3) and an annular diversion groove (5). The insulating glass guide section (3) is a ring-shaped sawtooth structure, coaxially arranged between the end of the cathode working tooth (1) and the front end of the rear guide (4). It is compatible with the spiral groove structure of the end of the cathode working tooth (1), the rear guide (4) and the guide groove (6) to achieve a smooth transition of the electrolyte in the flow channel of the cathode body. The insulating glass guide section (3) is adjacent to and continuously transitions with the insulating glass (2) that extends along the spiral direction, forming a continuous insulating guide section covering the end of the working tooth. The cross intersection gap at the intersection of the end of the working tooth and the insulating glass in the traditional cathode body is axially rearward, reducing the probability of sharp point puncture at the end of the working tooth. The annular diversion groove (5) is coaxially opened at the front end of the rear guide (4) and close to the end of the cathode working tooth (1). It is used to guide the electrolyte flowing out of the end of the working tooth to the groove for convergence and diversion under the drive of the electrolyte flow potential energy, eliminate the electrolyte accumulation phenomenon at the end of the working tooth, and work together with the insulating glass guide section (3) to solve the problem of high frequency ablation of the cathode body.

2. The short-circuit-proof cathode body structure for electrolytic machining of the inner bore of a complex irregularly shaped, gradient-shaped tube according to claim 1, characterized in that, The axial length of the insulating glass guide section (3) is 2-4 mm, with an optimal value of 3 mm.

3. The short-circuit-proof cathode body structure for electrolytic machining of the inner bore of a complex irregularly shaped, tapered tube according to claim 2, is characterized in that... The diameter of the annular diversion groove (5) is 24.7 mm, the groove width is 3-4 mm, and the optimal value is 3.5 mm; the axial distance between the right end face of the annular diversion groove (5) and the left end face of the insulating glass guide section (3) is 9-11 mm, and the optimal value is 10 mm.

4. The short-circuit-proof cathode body structure for electrolytic machining of the inner bore of a complex irregularly shaped, tapered tube according to claim 3, is characterized in that... The helix angle of the sawtooth structure of the insulating glass guide section (3) is completely consistent with the helix angle of the right-hand guide groove (6), and the top of the sawtooth smoothly transitions to the bottom of the guide groove (6), and the root of the sawtooth smoothly transitions to the wall of the guide groove (6).

5. The short-circuit-proof cathode body structure for electrolytic machining of the inner bore of a complex irregularly shaped, gradient-shaped tube according to claim 4, characterized in that, The length of the extended section of the insulating glass (2) matches the axial length of the insulating glass guide section (3), and the mating surface of the two is inclined and seamlessly fitted to form a continuous insulating barrier without breaks.

6. The short-circuit-proof cathode body structure for electrolytic machining of the inner bore of a complex irregularly shaped, gradient-shaped tube according to claim 5, is characterized in that... The cross-section of the annular diversion channel (5) is arc-shaped, the radius of the transition fillet between the bottom of the channel and the wall of the channel is 0.3-0.5mm, and the edge of the channel opening is blunted with a blunt radius of 0.2mm.

7. The short-circuit-proof cathode body structure for electrolytic machining of the inner bore of a complex irregularly shaped, tapered tube according to claim 6, is characterized in that... The end face of the cathode working tooth (1) is a circular arc transition end face with a radius of 0.5-1mm, and the circular arc transition end face is smoothly connected to the front face of the insulating glass guide section (3) without any steps.

8. The short-circuit-proof cathode body structure for electrolytic machining of the inner bore of a complex irregularly shaped, gradient-shaped tube according to claim 7, is characterized in that... The right-handed guide groove on the rear guide (4) and the right-handed guide groove (6) on the cathode working tooth (1) have the same helix angle and the same groove width, and their coaxiality is ≤0.01mm.

9. The short-circuit-proof cathode body structure for electrolytic machining of the inner bore of a complex irregularly shaped, gradient-shaped tube according to claim 8, characterized in that, After the electrolyte flows along the right-handed guide channel (6) to the end of the cathode working tooth (1), it is guided by the insulating glass guide section (3). 30%-40% of the electrolyte enters the annular diversion channel (5) to complete the convergence, diversion and buffering. The remaining electrolyte merges with the electrolyte flowing out of the annular diversion channel (5) and is discharged in an orderly manner along the guide channel of the rear guide (4).

10. The short-circuit-proof cathode body structure for electrolytic machining of the inner bore of a complex irregularly shaped, gradient-shaped tube according to claim 9, characterized in that, When using this cathode body to process the inner bore of complex irregularly shaped tubes, the cathode body has an ablation resistance processing life of ≥30 tubes / piece, the surface roughness Ra of the inner bore of the tube after processing is ≤0.4μm, and the dimensional accuracy of the cathode and cathode wires is ≤0.02mm.

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