Analysis and Test of Conductive Shaft of Large Horizontal NC ECM Machine Tool

Abstract

In order to solve the problems of serious heating and easy ablation of conductive shaft in electrochemical machining of special-shaped deep hole with large aspect ratio, the two schemes of single side copper bar and symmetrical copper bar of conductive shaft were studied by ANSYS software. And the conductive shaft scheme based on symmetrical copper bar scheme was determined. The thermoelectric coupling model of the conductive shaft was established to analyze the distribution law of temperature field and thermal deformation of conductive shaft under different working conditions. Through the machining test of special-shaped inner spiral deep hole parts with large aspect ratio, the results show that under the conditions of working current of 15 000 A, feed rate of 5 mm/min and continuous machining for 14 hours, the forming accuracy of the workpiece is ±0.15 mm and the surface roughness is better than Ra0.8 µm. The performance of the conductive shaft is stable and meets the actual processing requirements. The heat dissipation performance of the conductive shaft can be optimized by providing air flow on the upper surface and side at the same time.