Effects of Machining Parameters on Electrochemical Multi-Field Coupling

Abstract

Electrochemical machining involves three couplings between electric field, flow field and thermal field. The precipitation of hydrogen on the surface of the cathode will affect the entire electrochemical machining process and the final machining quality of the workpiece. Finite element software is used to analyze the effects of different voltages, electrolyte inlet pressure and interelectrode gap on current density, hydrogen volume fraction, conductivity and temperature distribution in this article. The research results show that the increase of processing voltage will increase the current density, hydrogen volume fraction and temperature, and decrease the conductivity of the solution. As the pressure of the electrolyte increases, the current density and conductivity increase, but the hydrogen volume fraction and temperature decrease. The current density, hydrogen volume fraction and temperature decrease, and the conductivity increases when the gap between electrodes increases. At the inlet, the current density and conductivity are relatively large, and gradually decrease along the electrolyte flow direction, while the hydrogen volume fraction and temperature are the smallest at the inlet, and gradually accumulate along the electrolyte flow direction, and reach the maximum at the outlet. Through multi-physics coupling simulation, the current density, temperature, conductivity and bubble distribution in electrochemical machining can be predicted, which can provide a theoretical basis for actual electrochemical machining process parameter selection.

Optimization and experimental study on cathode structure of electrochemical machining Titanium alloy inner helix

“…Mishra Technology studied the cathode structure based on the ow eld simulation model of transverse groove ECM, and concluded that symmetrical and uniform placement of cathode holes can improve the gap ow eld homogeneity [17]. In order to improve the forming accuracy, scholars have established a multiphysical eld coupling model of uid-electric-temperature structure to explore the variation law of electrolyte velocity and bubble distribution in the gap ow eld [18][19][20][21][22]. In the aspect of inner spiral parts with large aspect ratio process test, Mahdavinejad designed and optimized the cathode of small caliber gun barrel ri ing and carried out experimental research [23].…”