摘要 与传统机械加工方法相比，电解加工具有适合加工难加工类材料、无机械切削力等优点，这使它在枪炮、航空航天等制造业中得到成功应用，后又推广到汽车、拖拉机的模具制造中。航空航天、汽车制造、农用机械中涉及许多难加工材料的轴盘类以及薄壁类零件的加工，使用传统的机械切削加工方法存在无法避免的缺陷（如切削力大导致工件变形，切削热量大导致烧伤或产生微裂纹，且传统机械加工刀具磨损严重），甚至无法加工。本文涉及一种航空航天、农业机械等领域中难加工轴类零件、薄壁类零件的加工方法——电解车削加工方法，即用车削的运动方式电解加工工件。 数控电解加工是利用简单形状的工具阴极，通过计算机控制阴极相对于工件的运动来加工复杂型面，它既具有数控加工的柔性，又具有一般电解加工的优点。在电解车削加工中引入数控加工技术，用计算机控制阴极、工件联动成一定的轨迹，可用于加工较复杂的轴类零件，如偏心轮（轴）、凸轮等。 本文设计了一套数控电解车削加工的试验装置，并进行基础的试验研究。 试验装置的机械本体是一台普通机床CW6140，改造其三个方向的传动系统：X向（纵向）进给单元、Z向（横向）进给单元、C向（主轴）进给单元。各进给单元均由伺服电机经同步带减速传动。X向、Z向设计了滚珠丝杠精密传动。本文设计了一套能将干净电解液输送至加工区的电解液系统，压力、流量在一定范围内可调，设计的电解槽可对电解产物进行过滤、沉淀、收集，减少对环境的污染。 控制系统的基于PMAC运动控制器开发的控制系统。本文介绍了控制系统的硬件组成、基于PEWIN软件的系统配置方法，运动程序的编写方法。 对电解车削加工成型规律进行理论分析，在硬件建立的基础上进行相关工艺试验。通过平面加工实验、圆柱面实验，得出加工间隙和电流随速度（阴极进给速度、主轴旋转速度）的变化关系曲线，并分析了理论曲线与实际曲线存在差异的原因。进行较复杂回转表面（凸轮）的加工试验，加工的零件较好的满足了设计要求

ABSTRACT Compared with traditional methods, Electrochemical Machining (ECM) is suit for machining parts made of hard-to-machine materials, and there is no cutting force during the cutting course. Firstly, ECM had a successful use in the manufacturing of firearm and aerospace, and then it spread to the mould-making of autocar, tractor. There are many parts such as rotary ones made from hard-to-machine materials, thin walled parts. They are hard to machine by using traditional methods. A method used for machining these parts called Electrochemical Turning (ECT) is referred in this article. Numerical Controlled Electrochemical Machining (NC-ECM) uses a cathode of simple rectangle section. Through computer controlling, the cathode and workpiece move and form a certain track, so it can be used to machine complex surface. NC-ECM has both the advantage of NC machining and ECM. The technology of NC is used in electrochemical turning, make the cathode and workpiece move as a certain track, so NC-ECT can used to machine some complex surface of rotary parts, such as a cam, crank shaft and so on. An experimental equipment of NC-ECT was designed. Some basic experimental research was done based on the equipment. The body of the experimental equipment is a lathe named CW6140. The transmition systems of the lathe were changed: X feeding unit, Z feeding unit, C feeding unit. Each unit is drived by servo motor through synchronous belt. Ball screw precision transmitsion is designed in X and Z units. The designed electrolyte system can transport clean electrolyte to the machine area. The hydraulic pressure and flux can be adjusted in a certain range. A special electrolysis bath, which can gather and filtrate the products of electrolysis, is designed, to reduce the pollution to the environment. The control system is based on Programmable Muti-axis Controller (PMAC). The author discussed the hardware makeup and the program based on PEWIN. The shaping law of NC-ECT is analyzed in theory. Technical experiments had been done on the equipment. Through plat surface and rotary surface machining, the author achieved the gap and current change with the speed of cathode and spindle. There is a difference between the experimental data and theoretic data, the reasons of the difference are discussed. Some complex parts had been machined, such as a cam surface. The part meet the design requirement well.