In order to shorten the cathode design cycle and improve the forming accuracy of all-metal screw drill stator when electrochemical machining,a precision forming cathode design method based on particle swarm optimization BP neural network was proposed.A precision forming cathode design model for all-metal screw drill stator electrochemical machining was established,and the multi arc shaped cathode design was completed.Using self-developed large scale horizontal electrochemical machining equipment,stable machining of a 4-meter metal screw drill stator which made of 38CrMoAlA was achieved under selected parameter conditions.The contour forming accuracy reached±0.03 mm,and the surface roughness reached Ra0.848 μm.
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