Research on the Flow Field of Electrolytic Processing for Shaped Holes with Large Depth-to-diameter Ratio

Abstract For parts with large deep-diameter ratio shaped hole features, the complex structure of the profile and large deep-diameter ratio led to poor profile machining accuracy. The shaped hole processing requires high efficiency, high precision and low cost. Therefore, it is difficult to use the traditional processing method, and the electrolysis method based on the anodic dissolution mechanism is adopted, which has no shear stress and accurate profile forming. The 3D model is established based on the part, and the cathode and tooling structure is designed. Based on COMSOL software, we designed the flow channel uniformity of electrolytic processing of shaped holes and analyzed the arrangement of cathode outlet holes in electrolytic processing, which affects the uniformity of the processed surface and flow field. The arrangement of cathode exits holes to meet the uniform distribution of electrolyte at the surface boundary and high-speed flow at the surface was obtained by simulation analysis. By analyzing the flow field of different inlets, the flow rate magnitude of the shaped boundary and surface of the surface shaped hole is positively correlated with the inlet pressure of the electrode liquid.