Revolving cathode tool and method for co-rotating electrochemical machining of inner wall of aero-engine casing

1 . An apparatus for electrochemical machining an inner wall of an aero-engine casing, the apparatus comprising:

a power supply;

an anode workpiece comprising the aero-engine casing;

a revolving cathode tool for co-rotating electrochemical machining of the inner wall of the aero-engine casing, the revolving cathode tool comprising a cathode shaft, and a flexible cathode assembly,

wherein the cathode shaft is electrically connected with a cathode of the power supply, and the anode workpiece is electrically connected with an anode of the power supply;

one end of the cathode shaft is connected with the flexible cathode assembly;

an insulated window and a conductive sliding block are arranged on a side wall of the flexible cathode assembly;

the insulated window is matched in shape with convex structures in array distribution on an inner wall of the anode workpiece,

the conductive sliding block is matched in shape with convex structures in non-array distribution on the inner wall of the anode workpiece; and

the outer side of the conductive sliding block is flush with an outer side wall of the flexible cathode assembly.

2 . The apparatus according to claim 1 , wherein the flexible cathode assembly comprises a cathode body; the cathode body is of an annular structure; the insulated window is a penetrating port in a side wall of the annular structure; and the cathode body is internally provided with a positioning upright post, and an elastic mechanism is provided between the positioning upright post and the conductive sliding block.

3 . The apparatus according to claim 2 , wherein the elastic mechanism comprises a spring, a flexible window is provided on an outer side wall of the cathode body, the shape of the flexible window is matched with that of the conductive sliding block, the side wall of the cathode body communicates with the flexible window through a through hole, the inner side of the conductive sliding block penetrates through the through hole and is connected with one end of the spring, and another end of the spring is connected with a side wall of the positioning upright post.

4 . The apparatus according to claim 3 , wherein a stop nut is provided on the inner side of the conductive sliding block, and the radial size of the stop nut is larger than the diameter of the through hole.

5 . The apparatus according to claim 2 , wherein an upper end of the cathode body is provided with a cathode upper cover plate, and a lower end of the cathode body is provided with a cathode lower cover plate; and one end of the cathode shaft is connected with the cathode upper cover plate.

6 . The apparatus according to claim 2 , wherein an end of the non-array distributed convex structure is provided with an insulating sheet.

7 . The apparatus according to claim 6 , wherein the insulating sheet is made of a high-strength insulating material, and the insulating sheet has a thickness of 0.1 mm to 2 mm.

8 . A method based on the apparatus according to claim 1 , comprising the following steps:

during a machining process, connecting the flexible cathode assembly with the cathode of a power supply, connecting the anode workpiece with the anode of the power supply, and applying machining voltage; the anode workpiece rotates at a certain angular velocity, and a cathode shaft rotates in a same direction at a velocity which is n times of the angular velocity of the anode workpiece, and is fed along a radial direction;

attaching an insulating sheet to the surface of a non-array distributed convex structure on the surface of the anode workpiece in advance, and moving the flexible cathode assembly relative to the anode workpiece; when a conductive sliding block is in contact with the insulating sheet at a corresponding position, an elastic mechanism is compressed, and the conductive sliding block moves to the inside of a flexible window; and at this time, a machining current only exists in areas on two sides of the non-array distributed convex structure, so that a convex structure is generated;

moving the flexible cathode assembly relative to the anode workpiece; when the conductive sliding block corresponding to the surface of the anode workpiece is not attached with an insulating sheet, the conductive sliding block does not generate a reciprocating motion to keep flush with an outer circular surface of a cathode body; and a machining current exists in an area where an insulating sheet is not attached, so that the anode workpiece is uniformly corroded, leaving no convex structure.

9 . The method based on the apparatus according to claim 2 , comprising the following steps:

during a machining process, connecting the flexible cathode assembly with the cathode of a power supply, connecting the anode workpiece with the anode of the power supply, and applying machining voltage; the anode workpiece rotates at a certain angular velocity, and a cathode shaft rotates in a same direction at a velocity which is n times of the angular velocity of the anode workpiece, and is fed along a radial direction;

attaching an insulating sheet to the surface of a non-array distributed convex structure on the surface of the anode workpiece in advance, and moving the flexible cathode assembly relative to the anode workpiece; when a conductive sliding block is in contact with the insulating sheet at a corresponding position, an elastic mechanism is compressed, and the conductive sliding block moves to the inside of a flexible window; and at this time, a machining current only exists in areas on two sides of the non-array distributed convex structure, so that a convex structure is generated;

moving the flexible cathode assembly relative to the anode workpiece; when the conductive sliding block corresponding to the surface of the anode workpiece is not attached with an insulating sheet, the conductive sliding block does not generate a reciprocating motion to keep flush with an outer circular surface of a cathode body; and a machining current exists in an area where an insulating sheet is not attached, so that the anode workpiece is uniformly corroded, leaving no convex structure.

10 . The method based on the apparatus according to claim 3 , comprising the following steps:

during a machining process, connecting the flexible cathode assembly with the cathode of a power supply, connecting the anode workpiece with the anode of the power supply, and applying machining voltage; the anode workpiece rotates at a certain angular velocity, and a cathode shaft rotates in a same direction at a velocity which is n times of the angular velocity of the anode workpiece, and is fed along a radial direction;

attaching an insulating sheet to the surface of a non-array distributed convex structure on the surface of the anode workpiece in advance, and moving the flexible cathode assembly relative to the anode workpiece; when a conductive sliding block is in contact with the insulating sheet at a corresponding position, an elastic mechanism is compressed, and the conductive sliding block moves to the inside of a flexible window; and at this time, a machining current only exists in areas on two sides of the non-array distributed convex structure, so that a convex structure is generated;

moving the flexible cathode assembly relative to the anode workpiece; when the conductive sliding block corresponding to the surface of the anode workpiece is not attached with an insulating sheet, the conductive sliding block does not generate a reciprocating motion to keep flush with an outer circular surface of a cathode body; and a machining current exists in an area where an insulating sheet is not attached, so that the anode workpiece is uniformly corroded, leaving no convex structure.

11 . The method based on the apparatus according to claim 4 , comprising the following steps:

during a machining process, connecting the flexible cathode assembly with the cathode of a power supply, connecting the anode workpiece with the anode of the power supply, and applying machining voltage; the anode workpiece rotates at a certain angular velocity, and a cathode shaft rotates in a same direction at a velocity which is n times of the angular velocity of the anode workpiece, and is fed along a radial direction;

attaching an insulating sheet to the surface of a non-array distributed convex structure on the surface of the anode workpiece in advance, and moving the flexible cathode assembly relative to the anode workpiece; when a conductive sliding block is in contact with the insulating sheet at a corresponding position, an elastic mechanism is compressed, and the conductive sliding block moves to the inside of a flexible window; and at this time, a machining current only exists in areas on two sides of the non-array distributed convex structure, so that a convex structure is generated;

moving the flexible cathode assembly relative to the anode workpiece; when the conductive sliding block corresponding to the surface of the anode workpiece is not attached with an insulating sheet, the conductive sliding block does not generate a reciprocating motion to keep flush with an outer circular surface of a cathode body; and a machining current exists in an area where an insulating sheet is not attached, so that the anode workpiece is uniformly corroded, leaving no convex structure.

12 . The method based on the apparatus according to claim 5 , comprising the following steps:

during a machining process, connecting the flexible cathode assembly with the cathode of a power supply, connecting the anode workpiece with the anode of the power supply, and applying machining voltage; the anode workpiece rotates at a certain angular velocity, and a cathode shaft rotates in a same direction at a velocity which is n times of the angular velocity of the anode workpiece, and is fed along a radial direction;

attaching an insulating sheet to the surface of a non-array distributed convex structure on the surface of the anode workpiece in advance, and moving the flexible cathode assembly relative to the anode workpiece; when a conductive sliding block is in contact with the insulating sheet at a corresponding position, an elastic mechanism is compressed, and the conductive sliding block moves to the inside of a flexible window; and at this time, a machining current only exists in areas on two sides of the non-array distributed convex structure, so that a convex structure is generated;

moving the flexible cathode assembly relative to the anode workpiece; when the conductive sliding block corresponding to the surface of the anode workpiece is not attached with an insulating sheet, the conductive sliding block does not generate a reciprocating motion to keep flush with an outer circular surface of a cathode body; and a machining current exists in an area where an insulating sheet is not attached, so that the anode workpiece is uniformly corroded, leaving no convex structure.

13 . The method based on the apparatus according to claim 6 , comprising the following steps:

during a machining process, connecting the flexible cathode assembly with the cathode of a power supply, connecting the anode workpiece with the anode of the power supply, and applying machining voltage; the anode workpiece rotates at a certain angular velocity, and a cathode shaft rotates in a same direction at a velocity which is n times of the angular velocity of the anode workpiece, and is fed along a radial direction;

attaching an insulating sheet to the surface of a non-array distributed convex structure on the surface of the anode workpiece in advance, and moving the flexible cathode assembly relative to the anode workpiece; when a conductive sliding block is in contact with the insulating sheet at a corresponding position, an elastic mechanism is compressed, and the conductive sliding block moves to the inside of a flexible window; and at this time, a machining current only exists in areas on two sides of the non-array distributed convex structure, so that a convex structure is generated;

moving the flexible cathode assembly relative to the anode workpiece; when the conductive sliding block corresponding to the surface of the anode workpiece is not attached with an insulating sheet, the conductive sliding block does not generate a reciprocating motion to keep flush with an outer circular surface of a cathode body; and a machining current exists in an area where an insulating sheet is not attached, so that the anode workpiece is uniformly corroded, leaving no convex structure.

14 . The method based on the apparatus according to claim 7 , comprising the following steps:

during a machining process, connecting the flexible cathode assembly with the cathode of a power supply, connecting the anode workpiece with the anode of the power supply, and applying machining voltage; the anode workpiece rotates at a certain angular velocity, and a cathode shaft rotates in a same direction at a velocity which is n times of the angular velocity of the anode workpiece, and is fed along a radial direction;

attaching an insulating sheet to the surface of a non-array distributed convex structure on the surface of the anode workpiece in advance, and moving the flexible cathode assembly relative to the anode workpiece; when a conductive sliding block is in contact with the insulating sheet at a corresponding position, an elastic mechanism is compressed, and the conductive sliding block moves to the inside of a flexible window; and at this time, a machining current only exists in areas on two sides of the non-array distributed convex structure, so that a convex structure is generated;

moving the flexible cathode assembly relative to the anode workpiece; when the conductive sliding block corresponding to the surface of the anode workpiece is not attached with an insulating sheet, the conductive sliding block does not generate a reciprocating motion to keep flush with an outer circular surface of a cathode body; and a machining current exists in an area where an insulating sheet is not attached, so that the anode workpiece is uniformly corroded, leaving no convex structure.