Cathode cross tank and return hole optimization design and experiment verification of electrochemical machining closed integral impeller outside flow channels

Abstract

Electrochemical machining (ECM) cathode cross tank and return hole design is very crucial to machining aerospace closed integral impeller. In order to improve the precision of electrochemical machining closed integral impeller outside flow channels, the 3D cathode geometry model is developed by UG software, and the cathode structure flow field is simulated by COMSOL software. Through the flow field simulation, the width of cathode cross tank, the diameter, and the number of the electrolyte return holes were optimized. From the velocity cloud diagram, the simulation results show that the flow field is more stable and uniform under the parameters of electrolyte inlet pressure 0.4 MPa, 1.0-mm cross tank width, and the number of electrolyte return hole is 36 with 1.0 mm diameter. To verify the accuracy of the simulation result, the verified experiment was carried out. Finally, the experiment results were consistent with the simulation data. It indicates that electrolyte flow field simulation is an effective method to optimize cathode structure design. Utilizing this method can optimize the cathode structure and enhance the flow field stability during the processing of ECM. It can also reduce the cathode design cycle and cost.