Effects of Machining Parameters on Electrochemical Multi-Field Coupling

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.