In order to solve the issue of the poor rigidity of cathode structure in the electrochemical machining (ECM) of titanium alloy with high length-width ratio, a hollow slice cathode with stiffeners was designed. The effects of the num-ber of stiffeners and the angle between stiffener and sidewall on the overall rigidity of the cathode were studied by one-way fluid coupling analysis method. The simulation results show that the overall rigidity of the cathode is improved remarkably when three stiffeners are added to the cathode structure. In addition, the overall rigidity of the cathode decreases with the increase of the angle between stiffener and sidewall. Comprehensive cathode deformation and the maximum equivalent stress, the angle between stiffener and sidewall is 45°, the cathode structure has good rigidity, and can meet the rigid re-quirements. Finally, adopt self-developed experimental system to implement a ECM process test of deep narrow grooves with high length-width ratio. The optimized cathode structure can be used to process a deep narrow groove with length-width ratio of 11:1 and depth-width ratio of 9:1.%为解决钛合金大长宽比深窄槽电解加工过程中阴极结构刚性差的问题,设计了内部带有加强筋的镂空片状阴极结构,并采用单向流固耦合法研究了加强筋数量、加强筋与侧壁夹角对阴极整体刚性的影响规律.仿真结果表明,阴极结构添加3根加强筋时,阴极整体刚性得到显著提高.另外,阴极整体刚性随加强筋与侧壁夹角的增大而降低,综合阴极变形量与最大等效应力,确定了加强筋与侧壁夹角为45°时,阴极结构具有良好的刚性,能够满足试验要求.最后,采用自主研制的试验系统开展了大长宽比深窄槽电解加工工艺试验,选用优化后的阴极结构,可加工出长宽比11:1、深宽比9:1的深窄槽结构.
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