内花键电解整形阴极导流结构优化与试验

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关键词：电解整形加工；渐开线内花键；导流结构；流场设计；加工稳定性中图分类号：TH131.4DOI：10.3969/j.issn.1004-132X.2025.11.022

Abstract：Due to the complex profile and space limitations of involute internal splines，the uniformity of the flow field was difficult to control，which in turn made it difcult to improve the processing accuracy during electrochemical machining.The electrolyte flow mode，flow channel structure and processing mode were analyzed，a cathode flow guide structure was designed，and flow field analyses were conducted based on simulation platform.The results show that the inlet and outlet flow guide structure may eliminate flow field defects such as vortices，significantly increase the electrolyte flow rate in processing areas，and meet the requirements of electrochemical machining of involute internal splines.Processing experiments were carried out using the inlet and outlet flow guide structure. The machining processes are stable，the workpiece surface is bright and clean without marks，the roughness value Ra isas 0.8μm ，and the internal spline accuracy reaches level 5，verifying the rationality of the flow guide structure.

Key words： electrochemical machining；involute internal spline； flow-guiding structure； flow field design;processing stability

0 引言

在机械系统中有广泛应用的渐开线内花键截面结构复杂，精度要求高[1]，常使用插削、拉削等方式加工。（剩余9001字）