Abstract
In this work, a multi-physics field coupling model based on electric field, gas-liquid two-phase flow field and temperature field of the forward flow electrochemical trepanning (FFECT) blades was established, and the distribution law of hydrogen bubble volume fraction, electrolyte temperature and electrolyte conductivity in machining gap was obtained. Based on the simulation results, the time-varying process of electrolyte flow velocity distribution was divided into three stages according to the change in machining gap corresponding to different blade machining heights H, and the effects of the machining voltage U and the cathode feed rate v on the side gap Δ s and the end gap Δ e were investigated. The simulation analysis and experimental results show that both side gap and end gap increase as machining voltage increases while decrease with the increase in cathode feed rate. The model predictions are in good agreement with the experimental results, and the maximum errors of side gap and end gap are 10.6% and 17.7% respectively. In addition, the effects of machining voltage and cathode feed rate on the surface quality were studied experimentally. Results reveal that surface roughness can be reduced by appropriately decreasing the machining voltage and increasing the cathode feed rate.
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