Based On Flow Field Analysis Of The Spiral Electrode Electrochemical Machining Hole

Hole machining process has always been the difficulty in manufacturing. Traditional machining holes include drilling, punching and grinding holes, and so on,but the traditional processing in some high hardness materials such as tungsten carbide, abrasives, etc, just seems very weak, is not only inefficient process, but also in the processing quality is difficult to guarantee. Electrochemical machining(ECM) is a new processing technology of the last century, is one of the important technology of machining holes in the 21 st century. ECM is the essence of the process of galvanic corrosion of the particles, any conductive material can be processed in theory, at the same time due to the removal of material in the form of ions, it is possible to ensure the quality and precision machining. For ECM, at home and abroad have done a lot of research, its research field is different, some processing voltage magnitude, some concentration of the electrolyte and so on, from the little from the machining gap in electrolyte flow angle for the direction and movement of the starting point for the study of electrolytic particles. In this paper, the process of simulation analysis, a theoretical model is first established in electrochemical machining, and then the model is imported to ICEM mesh and boundary condition(here just sets the name, following the parameters in the CFD pretreatment in), then draw a good mesh import CFX to set specific parameters and operation, the operation results in CFD-POST processing.In this paper mainly do the following work.Cylindrical electrode was studied under the condition of the different speed at the bottom of the side of the flow field and flow field. Through simulation of cylindrical electrodes, analyzes the movement of the particles at the bottom and sides of the cylindrical electrodes, results showed that the rotation will make the electrolysis electrode particles flow into the machining gap, and if the speed, the higher the speed, the faster the flow of particles, but we also found that if the speed is too high, it will make the particles collide electrodes, and the particles accumulate at the bottom of which affects the processing efficiency. Therefore, only under the condition of specific speed to the largest electrolytic machining efficiency into full play.Spiral electrode was studied under different rotating speed of the flow field analysis. Through simulation we got really make the spiral electrode to increase process efficiency, because the special shape spiral electrode such that the electrolysis process flow field distribution has changed, at the same time generating a velocity in the Z direction, thus accelerating the electrolysis particles movement, so that the particles can escape better machining gap. We take the particles as the research object, the pressure gradient and flow of particles are analyzed respectively, in theory if they value the greater the electrochemical machining will be more beneficial to us. We found that the high pressure gradient and flow rate will increase the speed, theoretically more conducive to our processing, with cylindrical electrode is the same, but the speed is too high will make particles collision electrolytic particles is difficult to escape, and accumulate at the bottom, so that affect machining efficiency. As a result, the spiral electrode to improve the efficiency of the electrochemical machining, but only specific speed can be conducive to the electrochemical machining.Although we obtained by analyzing the helical electrode in favor of machining, but for the parameters have not discussed helical electrode, and finally through the four parameters(Pitch, Bottom width, Groove depth and helix angle) we helix electrode of orthogonal experiment under certain rotational speed conditions. Through the four factors three levels orthogonal experiment set up nine different set of electrodes, the pressure gradient and flow analysis, we get: For pressure analysis, pitch and groove depth is smaller, the wider the bottom slot the greater the pressure gradient, for the traffic we get, the smaller the pitch of the bottom groove width greater the traffic. From the physical point of view the analysis we can get, the greater the flow rate and pressure gradient will take more electrolysis particles, the more favorable electrochemical machining. Therefore, the right to reduce the pitch and an appropriate increase in the width of the bottom groove will be beneficial to the electrolytic machining gap particles escape, help to improve the efficiency of the electrolysis process.