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

• Published in: International journal of advanced manufacturing technology Vol. 133; no. 7-8; pp. 3663 - 3671
• Main Authors: Tang, Lin, Wang, Yi, Zhang, Jingjing, Zhang, Jun, Cao, Tong, Deng, Wen
• Format: Journal Article
• Language: English
• Published: London Springer London 01.08.2024; Springer Nature B.V
• Subjects: Algorithms; Back propagation networks; CAE) and Design; Camber; Cathodes; Computer-Aided Engineering (CAD; Design optimization; Design techniques; Electrochemical machining; Electrolytes; Engineering; Industrial and Production Engineering; Inlet pressure; Mechanical Engineering; Media Management; Neural networks; Original Article; Particle swarm optimization; Precision forming; Stators; Surface roughness; All-metal screw drill stator; Electrochemical machining (ECM); BP neural network; Cathode design; Particle swarm optimization algorithm
• ISSN: 0268-3768; 1433-3015
• DOI: 10.1007/s00170-024-13910-3

In order to shorten the cathode design cycle, reduce design cost and improve forming accuracy for all-metal 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 camber feed cathode design. By using self-developed large scale horizontal CNC electrochemical machining equipment, under the condition of voltage 19 V, electrolyte 15%NaCl, electrolyte temperature 35 ± 1℃, electrolyte inlet pressure 1.6 MPa, and feed speed 10 mm/min, the stable and reliable electrochemical machining processing of the 4-m length of 38CrMoAlA all-metal screw drill stator was completed. The contour forming accuracy is ± 0.03 mm, and the surface roughness is Ra0.848 μm. Research showed that it is an efficient and feasible method to design the electrochemical machining camber feed cathode of all-metal screw drill stator using PSO-BP neural network.