Research on the precision forming cathode design method of electrochemical machining all-metal screw drill stator

Abstract

In order to shorten the cathode design cycle, reduce design cost and improve forming accuracy for allmetal screw drill stator electrochemical machining (ECM), this paper proposed a precision forming cathode design method based on particle swarm optimization BP neural network (PSO-BP). The cathode design algorithm model of all-metal screw drill stator electrochemical machining was established, completed the three-side feed cathode design. By using self-developed large scale horizontal CNC electrochemical machining equipment, under the condition of voltage 19V, electrolyte 15%NaCl, electrolyte temperature 35 ± 1℃, electrolyte inlet pressure 1.6MPa, and feed speed 10mm/min, the stable and reliable electrochemical machining processing of the 4-meter length of 38CrMoAlA all-metal screw drill stator was completed. The contour forming accuracy is ± 0.03mm, and the surface roughness is Ra0.848µm. Research showed that it is an e cient and feasible method to design the electrochemical machining three-side feed cathode of all-metal screw drill stator using particle swarm optimization BP neural network. Highlights► The structure of the inner hole of the all-metal screw drill is complicated and the precision is di cult to control, which brings great di culties to the manufacture.► In order to improve the quality of electrochemical machining, particle swarm optimization BP neural network was used to design the three-sided feed cathode for electrochemical machining.► The cathode design algorithm model of all-metal screw drill stator electrochemical machining was established, completed the three-side feed cathode design.► Using particle swarm optimization BP neural network to design cathode is an effective method to improve the accuracy of electrochemical machining.