Flow field and temperature field analysis of three-sided feed cathode for deep special-shaped hole in ECM

Electrochemical machining has the characteristics of no loss of processing cathode, high processing efficiency and good accuracy, and can process complex deep special-shaped holes at one time with simple feed motion. This paper uses electrochemical machining technology to solve the problem of complex deep special-shaped holes that are difficult to machine and designs a three-sided feed-type cathode. Firstly, the gap electric field was simulated and analyzed using COMSOL simulation software. The simulation results show that the width of the insulating layer on both sides of the end and wall of the cathode key tooth slot tip is 0.5 mm, and the rounded angle formed by the deep special-shaped hole key tooth tip is reduced to 0.11 mm after machining. Secondly, a simulation analysis of the gap electrolyte flow field and temperature field was carried out. The simulation results show that the gap electrolyte flow velocity is higher and the flow uniformity is better for the cathode structure with 10 through-holes, and the temperature of the gap electrolyte can be controlled below 30 & DEG;C, which significantly improves the forming accuracy of the deep special-shaped hole. Finally, process tests were carried out and the best combination of process parameters was obtained by the S/N ratio and grey correlation method. The simulation effectively shortens the cathode development cycle and optimizes the cathode structure.