A combined process of electrochemical machining and slotting for semi-blind hole involute internal splines enhanced by a new cathode design

Abstract Machining complex internal structures in high-hardness materials presents a significant challenge. Conventional cutting methods often suffer from issues such as extensive tool wear and prolonged production cycles. This research proposes a combined process that integrates roughing electrochemical machining (ECM) with a precision slotting to achieve fast involute internal spline shaping of intricate high-hardness components. To enhance the process stability of the spline ECM process, a curved cathode design tailored for ECM is introduced. Flow field simulations demonstrate that the proposed curved cathode design leads to a relatively uniform distribution of electrolyte flow in the machining area. A dedicated ECM fixture and system are established for conducting experiments. The obtained ECM outcomes substantiate the commendable capacity of the optimized curved cathode to accomplish high precise and efficient machining and shaping of splines. Consequently, the optimized curved cathode design exhibits substantial potential for widespread application in the large-scale production of intricate internal cavity components composed of challenging-to-machine materials.