Study Of Temperature Domain Based On Multi-physics Coupling Simulation In PECM

In the pulse electrochemical machining(PECM),the physical and chemical characteristic of interelectrode gap will be improved significantly,and the machining accuracy and surface quality will be enhanced.However,pulse electrochemical machining also has the disadvantages of direct current electrochemical machining.In order to solve the defects of PECM,it is necessary to simulate the machining process.In the electrochemical machining,the distribution of temperature will affect the electrical conductivity and current efficiency.Thus the changes of temperature have a great influence on the machining accuracy.This paper researches the distribution of temperature in PECM.Based on the research of the temperature field,it will be more accurate to predict the surface of anode.Thus it will greatly reduce the time of test and cathode design,and save the cost.The multi-ion transport and reaction model can reflect ion migration,diffusion,convection and concurrent electrode reaction in truth,such as metal dissolution and precipitation of oxygen in anode.Through the simulation analysis,the function expression of current efficiency and current density have been fitted.And the relationship of temperature,current efficiency,electric conductivity and electrode polarization have been obtained.The coupling simulation model of PECM based on potential model has been established.From the simulation we can obtain the change law of temperature in single pulse cycle and the relationship between processing parameters and temperature distribution in gaps.At the same time,the functions of current efficiency-temperature and conductivity-temperature have been introduced in the model.And the dynamic simulation of PECM has been set up by COMSOL with MATLAB.Through the experiment of plate electrode electrochemical machining and the experiment of blade electrochemical machining,it is found that the simulation calculation of current efficiency based on the multi-ion transport and reaction mode is accurate and reliable.And the dynamic simulation about blades in the electrochemical machining based on voltage model has to be further optimized.