Characteristics of Flow Field in Electrochemical Machining of Square Holes
To solve the problems of sharp corners that square holes have and uneven flow field and dead zone in the machining gap during electrochemical machining,the paper proposes two methods for correcting the position and the number of liquid inlets and modifying the shape of cathode head.The flow field of electrochemical machining gap was simulated and verified with COMSOL simulation software,and then the inlet pressure of a flow field was numerically simulated to optimize the flow field of square holes,on the basis of which square holes were electrochemically machined ultimately.The findings are as follows.When the inlet is facing the corner,the results obtained are better than those by other methods.Rounding the sharp corner at the cathode can better uniform the flow field of the edge line.When the fillet is 0.3 mm,the whole side line in the flow field is more uniform and the flow rate is more reasonable.The square holes machined with the cathode with a 1mm corner exhibit the best machining effect.
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