Electrochemical machining flow field simulation and experimental verification for irregular vortex paths of a closed integer impeller

Abstract

Electrochemical machining (ECM) is an economical and effective method for machining hard-to-cut metal materials into complex shapes in aerospace and aeronautics fields, which are difficult to machine with conventional methods. As we all know, electrolyte flow field is one of the important factors in ECM irregular vortex paths of the closed integer impeller. To improve the stability of the whole processing, the flow field mathematical model was developed. The 3-D gap flow field simulation models of the reversed flow and forward flow patterns were also established, respectively. From the streamline, velocity, and pressure cloud picture of the electrolyte flow field simulation, the results showed that under the reversed pattern, the electrolyte flow velocity in the front gap and the side gap was not only higher but also more uniform than the forward pattern. Finally, the experimental verification was carried out and the experimental results were consistent with the simulation results. The whole process is stable and has no spark and no short circuit phenomenon with the reverse flow pattern. We successfully obtained 0.8-micron surface roughness of the machined workpiece. On the contrary, the irregular vortex paths cannot be successfully processed by forward flow pattern. The results indicate that reverse flow pattern is an effective and feasible method to machining irregular vortex paths of the closed integer impeller.

Study on Improving Electrochemical Machining Performances through Energy Conversion of Electrolyte Fluid

“…Tang et al compared the influence of different flow modes on ECM of a closed integer impeller. The results showed that the reverse flow mode achieved a higher electrolyte velocity and better machining results than the forward flow mode [18].…”

Multi-field Coupling Analysis of Electrolytic Machining of Magazine Mounts Based on COMSOL

“…Li et al [8] simulated and tested the flow field of spin-printed electrolytic processing tabs, and the simulation analysis results showed that the flow field of spin-printed electrolytic processing was changing periodically; Liu et al [9] proposed a three-dimensional composite electrolyte flow field model for the electrolytic processing of engine blade discs, which improved the flow field state in the flow channel mutation region and effectively suppressed the flow field defects in the two -dimensional flow field;. Liu et al [10]used the "bi-directional feed" electrolyte flow mode for engine blade machining, which improved the machining quality of the blade; Tang et al [11] improved the stability of the electrolytic machining process by performing flow field analysis on the 3D gap flow field simulation model with reverse flow and forward flow. Liu et al [12] established A mathematical model of multi-physical field coupling in the process of reaming electrolytic processing in small holes,simulated using COMSOL Multiphisics software to obtain the flow rate distribution, current density distribution and temperature distribution in the processing gap, and the effects of different processing times and voltages on the temperature distribution were analyzed.…”

Simulation and experiment research on liquid channel of diffuser blade by electrochemical machining

“…In addition, in the study of flow field mode, in 2013, Xu et al used Π shape flow mode to ECM the integrated blade cascade channel, and a more uniform flow field improved the processing quality, stability and efficiency [19]. Two years later, the reverse flow field was used to ECM for the closed integral impeller, showing that the whole process was stable, and the machining quality was high [20]. In 2020, Wang et al designed a new tangential flow field, which effectively eliminated the defect of sudden change of flow channel in ECM for large size blade [21].…”