Investigation of electrochemical machining for gradual change special-shaped deep spiral hole based on COMSOL

Abstract

Aiming at the unachievable problem for the continual change special-shaped deep spiral hole by traditional machining methods, the electrochemical machining (ECM) was employed. The electric field mathematical models of ECM gap were built, and the distribution of electric field was simulated for the gradual change special-shaped deep spiral hole. The simulated results showed that the distribution of electric lines is uneven, and the dense region of electric lines causes the irregular local shape, and the distribution of electric field can be improved by optimizing the shape size of final forming area of cathode machining section. The process experiments were conducted for specific technological parameters, and the test samples were sliced and measured to obtain the law of the mapping relation between process parameters and machining size. The process experimental results showed that as the voltage changes in the range of 12~18 V, the groove width variation is 0.3 mm, the diameter variation is 0.5 mm for the forming gradual change section size, and the average voltage increases by 2 V, the size of groove width by 0.1 mm, and the diameter by 0.18 mm. Utilizing COMSOL to simulate machining gap electric field can optimize the cathode structure, and control the continual change of process parameters of ECM, and finally realize the gradual change of special-shaped section size.