Analysis of electrochemical machining of involute internal spline by foamed metal cathode

The foamed metal material is novelty applied to manufacture the tool cathode to realize the electrochemical machining(ECM)of involute internal spline of difficult-to-cut materials. The porosity and electrolyte flow characteristics of the foamed brass cathode are analyzed. The geometric and mathematical model of involute internal spline by ECM is built, and the relevant electric field simulations with different machining voltages, electrolyte types and cathode feed rates which directly determined the ECM results are conducted by COMSOL Multiphysics software. From the simulation results, the suitable process parameters are obtained and then carried out process experiments. The experiment results show that the foamed metal material can be used to fabricate the tool cathode for ECM. And when the machining voltage is 10 V, the electrolyte is 2% NaCl + 8% NaNO 3 solution, the cathode feed rate is 1.00 mm/min, the involute internal spline formed by axial ECM can get a better profile which basically meets the finishing requirements. The application of the foamed metal cathode laid a new technical foundation for the ECM to manufacture complex internal structures and from design theory to contemporary industrial praxis.