Real-Time Observation of Multiphysics Coupling Fields in the Electrochemical Trepanning of Vibrating Cathodes

Abstract

An electrochemical trepanning (ECTr) processing system with an observable inter-electrode gap (IEG) is designed to study the effects of vibrating cathodes on the IEG distribution. A multiphysics coupled field model for a vibrating cathode ECTr with electric, gas-liquid two-phase flow, and temperature fields is developed based on this system. The distribution laws of the current density, bubble volume fraction, and temperature in the IEG are obtained via multiphysics simulations of the coupled fields. Compared to conventional ECTr, the current density within the IEG increases, the end-gap current density percentage grows by 3%, and the electrolyte renewal within the IEG is promoted. An experimental study of a vibrating cathode ECTr verifies the validity of the simulations. A distinct white bubble layer appeared at the transition corner of the end gap near the cathode side. The bubbles were gradually increasing as the cathode was fed to the workpiece during a cycle. No obvious white bubble layer is seen at the side gap. The observations verify the multiphysics field simulations to study the gas volume fraction distribution law. The experimental results show that the vibrating cathode improves the integrity of the blade profile and surface quality.