Multiphysics Problem Numerical Simulation On High Frequencuy Microsecond Pulse Electrochemical Machining

The metal was wiped off or added when the reaction of the oxidation and deoxidization were occurred in electrochemical machining (ECM). It will be tremendous potential in the micro-manufacturing field with advantages as high machining efficiency, wide materials suit to fabricate, no residual stress and no heat treatlnent borne on the work piece surface.Developed with the modern electric and electron technology, the direct current power supply was substituted by the pulse power supply aimed to satisfy the requirements of machining precision and surface roughness in ECM, and the frequency of the pulses power supply became higher and higher. Microsecond pulse electrochemical machining improves machining accuracy and surface quality effectively, it improves the level of Electrochemical machining to exact Machining.Multiphysics problems (MPPS) are phenomena produced by interaction between two or more fields in a system, which exist widely in nature, and brought out more and more in products such as delays, MEMS, engines, gas turbines and so on. In such cases, no reasonable calculation or simulation results can be gotten if only single field is analyzed. With the rising of the capability of computer and software, comes a trend that the FEM method is used more and more to solve multiphysics problems. Some experts even said the simulation of multiphysics problems will be the future of FEM.The electrochemical machining process is a comprehensive processing technology, which contains electrochemistry, fluid mechanics, mechanics and so on. It deals with electric field, liquid field and temperature field. The application of multiphysics problems simulation technology in electrochemical machining process is helpful to guide the design of electrodes, to improve the process parameters, and to reduce the prepare times.The basic principle of electrochemical machining and the High Frequency Short Pulses Electrochemical Machining (HSPECM) were introduced in this thesis. The coupling relationships between the fields existed in the electrochemical machining process and the basic theory of the fields were analyzed. The two-dimensional geometry model of the electrochemical machining field for a blade was established with AutoCAD, and was then imported into COMSOL V4.3b for a pre-treatment and grid-divide. Under the consideration of the coupling relationship between electric field and liquid field, the two-dimensional flow field and the electric field was simulated by the usage of COMSOL V4.3b. Through the comparison and analysis of the electrical conductivity and current density value velidated the advantage of high frequency narrow pulse electrochemical machining and provided important references for the design of electrodes and the optimization of process parameters, and laid a foundation for the future research task:the simulation of whole process of electrochemical machining.