Research on simulation method of multiple time scales dissolution process in tube electrode pulse electrochemical machining

Abstract

Tube electrode pulsed electrochemical machining (TE-PECM) has received widespread attention as an electrochemical perforation technique that is widely used for machining deep small holes/oblique small holes such as air film holes in blades. However, the TE-PECM process is characterized by complex multi-physics field coupling relationships and multiple time scales for multi-physics interactions, making the simulation of the pulsed electrolytic processing process computationally huge and difficult to perform. To accurately describe the multi-physical field coupling relationship for pulsed electrochemical processing. In this paper, a k-ε gas-liquid two-phase flow model has been introduced to model the interpolar gas-liquid two-phase flow field variation law, and on this basis, a coupled multi-physics field model for pulsed electrochemical machining processing is established to provide an accurate description of the interpolar multi-physics interaction mechanism. A quasi-steady-state iterative simplification algorithm based on heat source averaging is proposed to solve the problem that the time scale span of the dissolution process leads to a huge amount of simulation calculations. The simulation analyzes the dissolution characteristics at the micro time scale and macro time scale and compares them with the full precision method. The results show that the simulation accuracy of the two methods is the same, but the simulation calculation time of the simplified algorithm is reduced by two-thirds. The experimental platform was designed and built to carry out a series of experiments under different processing times, and the results effectively verified the correctness of the simulation method.