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.