Abstract

A new multi-physics model is presented for numerical simulation of the precise electrochemical machining process with pulsed current and vibrating cathode. The method includes the change of electric field, flow field, temperature field and geometric deformation field. Meanwhile, the effects of cathodic vibration on electrolyte velocity is obtained by transient simulation of flow field and the velocity distribution obtained from the multi-step steady state flow field is compared with that of transient flow field. To solve the problem that machining process simulation needs a lot of computing time, a multi-step steady state flow field solution and a loop iterative solution algorithm based on COMSOL are presented, and the error analysis was carried out. The results show that the algorithm can ensure the error within a reasonable range and greatly reduce the calculation time.

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