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<p>Electrochemical machining (ECM) is an advanced processing technology widely used in fields such as aviation, aerospace, and mold manufacturing. For the process of gas-film-assisted electrochemical machining, this paper develops a multiphysics model considering the coupling of electric field and multiphase flow to delve into its dynamic forming mechanism. The research systematically examined how the generation of a stable gas-insulating film under different gas flow conditions effectively suppresses stray corrosion. The gas-phase volume fraction, current density distribution, and dynamic evolution of workpiece geometry was quantitatively investigated through numerical simulations. Simulation demonstrated that increasing gas flow within optimal parameters significantly promotes uniform gas film distribution, reduces stray current effects, and enhances machining accuracy. Experiments were conducted to validate these results that upon increasing the gas flow rate from 0 to 1.5 <InlineEquation ID="IEq1"> <EquationSource Format="TEX">\(\text {m}^3/\text {h}\)</EquationSource> </InlineEquation>, the radial error decreases from 0.134 <InlineEquation ID="IEq2"> <EquationSource Format="TEX">\(\text {mm}\)</EquationSource> </InlineEquation> to 0.047 <InlineEquation ID="IEq3"> <EquationSource Format="TEX">\(\text {mm}\)</EquationSource> </InlineEquation>, and the surface roughness decreases from 1.73 <InlineEquation ID="IEq4"> <EquationSource Format="TEX">\(\mu \text {m}\)</EquationSource> </InlineEquation> to 1.35 <InlineEquation ID="IEq5"> <EquationSource Format="TEX">\(\mu \text {m}\)</EquationSource> </InlineEquation>. The simulation and experimental results confirm the accuracy and effectiveness of the multi-physics coupling dynamic forming model, providing theoretical support and technical guidance for the optimization of electrochemical machining processes.</p>

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Study on the forming mechanism of gas film insulation assisted electrochemical machining based on multi-physics coupling model

  • 期刊论文

  • 发表日期：

    2026年2月28日

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  • Zhouzhi Gu,
  • Xu Pei,
  • Xinwu Zhang,
  • Longwei Xiao,
  • Xiaobo Liang

摘要

Electrochemical machining (ECM) is an advanced processing technology widely used in fields such as aviation, aerospace, and mold manufacturing. For the process of gas-film-assisted electrochemical machining, this paper develops a multiphysics model considering the coupling of electric field and multiphase flow to delve into its dynamic forming mechanism. The research systematically examined how the generation of a stable gas-insulating film under different gas flow conditions effectively suppresses stray corrosion. The gas-phase volume fraction, current density distribution, and dynamic evolution of workpiece geometry was quantitatively investigated through numerical simulations. Simulation demonstrated that increasing gas flow within optimal parameters significantly promotes uniform gas film distribution, reduces stray current effects, and enhances machining accuracy. Experiments were conducted to validate these results that upon increasing the gas flow rate from 0 to 1.5 \(\text {m}^3/\text {h}\) , the radial error decreases from 0.134 \(\text {mm}\) to 0.047 \(\text {mm}\) , and the surface roughness decreases from 1.73 \(\mu \text {m}\) to 1.35 \(\mu \text {m}\) . The simulation and experimental results confirm the accuracy and effectiveness of the multi-physics coupling dynamic forming model, providing theoretical support and technical guidance for the optimization of electrochemical machining processes.