Experimental investigation of electrochemical machining for involute internal spline using cathode working teeth sheet with circumferential vibration.

Manufacturing internal splines with complex structures in high-hardness materials poses challenges in conventional machining processes. This paper introduced a new electrochemical machining (ECM) method using an assembled tool cathode with a cathode working teeth sheet with circumferential vibration for efficient and stable shaping of involute internal splines of intricate high-hardness components. A detailed design of the assembled tool cathode is presented, accompanied by flow field simulations analysing electrolyte distribution during circumferential vibration. A specific experimental system, fixture, and a used electrolyte filter module were constructed for spline ECM experiments. The results show that with the cathode feed rate of 2.7 mm/min, and the circumferential vibration frequency of 80 Hz, the involute internal spline profiles were successfully shaped with higher precision and efficiency with less appropriate allowance. • A novel ECM approach featuring an assembled tool cathode, equipped with teeth that vibrate circumferentially, is introduced for enhanced machining. • Circumferential vibration of the cathode is shown to improve electrolyte distribution in the area where tooth roots are machined, facilitating better machining outcomes. • An experimental ECM system for spline machining, complete with a dedicated fixture and a module for filtering used electrolyte, has been developed. • Utilizing a cathode feed rate of 2.7 mm/min and a vibration frequency of 80 Hz, precise involute internal spline profiles are achieved with minimized excess material. [ABSTRACT FROM AUTHOR]