Multi-physical field simulation and experimental verification of electrochemical machining of curved holes

Curved holes formed by sweeping curve of spherical contour are often used in disc brakes and continuously variable transmissions and can be efficiently machined by electrochemical machining. In the present study, the electrochemical machining process of curved ball groove is simulated under multi-physical field coupling to analyze the effects of the initial gap, electrode voltage, and inlet pressure on the electrolyte flow rate, interelectrode temperature distribution, and gas bubble rate. The optimal parameters of multi-physics coupling simulation are used for experimental verification, and an ideal test workpiece is obtained.