523 Development of an Electrochemical Machining Method for Machining Curved Holes

抄録

A method has been developed for machining the coolant channels of molds and other types of curved holes using the simplest possible equipment. This method focuses on the use of a flexible tool to machine a curved hole by following a small hole formed by the same tool, instead of applying an actuator to control the tool shape. It was confirmed in machining tests that the curvature and shape of curved holes can be controlled by varying the rotational speed of the electrode and the electrolyte pressure. An investigation was made of the machining speed, taking into account the application of the new method to actual molds. It was found that a machining speed of approximately 2 mm/min was the limit when machining aluminum. This speed limitation is due to the boiling of the electrolyte around the electrode because of the heat generated during machining. Moreover, in actual machining operations, it is necessary to measure the position of a curved hole as it is being machined. Accordingly, an investigation was also made of a method for measuring the position of the electrode while machining a curved hole.