Abstract: In order to further improve the process stability in electrochemical machining of involute internal splines， the influence rules of electrolyte flow pattern， tool cathode structure and electrolyte parameters on the flow field distribution were discussed based on numerical analysis. The numerical analysis results show that the side flow of electrolyte may enhance the uniformity of electrolyte velocity distribution at the inlets of the machining regions， and the variable cathode with guide may reduce the velocity fluctuation of workpiece surfaces. In view of the process stability and localization， the electrochemical machining tests of the involute internal splines were carried out. The testing results show that the feed rate may reach more than 2.1 mm/min， the tooth profile deviation may be controlled within 0.015  mm， the helical deviation may be controlled within 0.02 mm when the processing depth is as 30 mm. The efficiency and precision of machining method may meet many practical requirements and has obvious technical and economic advantages.

Key words:  , electrochemical machining, involute internal spline, flow field design, process stability 

摘要： 为进一步提高渐开线内花键电解加工的工艺稳定性，基于数值分析方法探讨了电解液流动方式、工具阴极结构、电解液参数对流场分布的影响规律。数值分析结果表明：电解液侧向流动可以改善加工区入口处电解液流速分布均匀性；带有导流段的变截面阴极能够降低工件表面流速波动。针对工艺稳定性及加工定域性，开展了渐开线内花键电解加工试验研究。试验结果表明：进给速度可达2.1 mm/min以上，齿形误差可控制在0.015 mm以内，当加工深度为30 mm时，齿向误差在0.02 mm以内。该加工方式的效率及精度能够满足很多实际需求，具有明显的技术经济优势。

关键词: 电解加工, 渐开线内花键, 流场设计, 工艺稳定性