异形型腔电解加工多物理场耦合仿真研究

Study on Multi-Physical Field Coupling Simulation of Electrochemical Machining of Special-Shaped Cavity

为研究在多物理场耦合作用下,不同入口流速对异形型腔电解加工成型精度和形貌变化的影响规律,文中以“T”形型腔为研究对象,建立了电场、流场、温度场及结构场的多物理场耦合仿真模型,基于COMSOL软件仿真计算得到了在不同入口流速时,间隙内电解液流速、温度、电流密度的分布和加工工件表面形貌的变化规律。结果表明:入口流速为6m·s^(-1)及以上时,间隙内电解液流速均大于5m·s^(-1),减少和避免钝化现象的产生;加工电压15V,入口流速15m·s^(-1)时,间隙内电解液最高温度为24.2℃,工件阳极表面电流密度分布更均匀,工件加工精度和表面形貌好,为复杂异形型腔电解加工提供工艺技术参考。

In order to study the influence of different inlet flow rates on electrochemical forming accuracy and morphology change of special-shaped cavity under the coupling action of multi-physical field,a multi-physical field coupling simulation model of electric field,flow field,temperature field and structure field was established based on the study of T-shaped cavity.The electrolyte flow rate,temperature and structure field in gap were obtained by simulation calculation based on COMSOL software at different inlet flow rates,distribution of current density and variation of surface morphology of machined workpiece.The simulation results show that when the inlet flow rate is 6m·s^(-1) or above,the electrolyte flow rate in the gap is more than 5m·s^(-1),which can reduce and avoid the passivation phenomenon.When the processing voltage is 15Vand the inlet flow rate is 15m·s^(-1),the maximum temperature of electrolyte in the gap is 24.2℃,the current density distribution on the surface of the anode of the workpiece is more uniform,and the machining accuracy and surface morphology of the workpiece are good,which provides technical reference for electrolytic machining of complex profile cavity.