旋转超声电解复合加工小孔流场仿真

为解决电解加工深小孔中电解液难以进入加工区和电解产物难以排出的问题，构建了内喷式旋转超声电解复合加工装置，进行了电解加工、旋转电解加工和旋转超声电解复合加工小孔的对比试验。试验结果表明，阴极旋转能明显提高孔的圆度，旋转超声电解复合加工具有最大的平均加工电流，所加工孔的直径、深度都为三者中最大，表明其材料去除率是最大的。在此基础上，利用有限元ANSYS CFX软件,建立了气液两相流三维气穴模型，分析了阴极旋转和阴极高频振动对电解加工流场、电场的影响。仿真结果表明：阴极旋转使得气泡在阴极表面聚集，不利于气泡的排出，阴极振动加速了电解液的运动，有利于气泡的排出，因此具有最大的材料去除率。

Flour Field Simulation of Small Holes Machined by the RUECM

In  order to solve the difficulties to update the electrolyte and discharge the products in  the electrochemical machining(ECM)  for deep-small holes,  the internal rotary ultrasonic electrolytic composite machining device  was  constructed,and  the comparative experiments of  ECM,rotary electrochemical machining(RECM) and RUECM were carried out.The results show that the roundness of holes is improved by the rotation of cathode and the average current  is the largest in the RUECM,thus the diameter and the depth of the holes machined by  RUECM are the  largest, which indicates that the material removal rate (MRR) is  the greatest, too. Based on those, the effects of the rotation and vibration of cathode on the flow field and electric field  were  analyzed by ANSYS CFX with the three-dimensional two-phase flow cavitation model. The simulation results show that when cathode rotates,the air bubbles are gathered on the cathode surfaced,which is not conducive to the discharge of air bubbles; when   cathode vibrates,the motion  of electrolyte is accelerated,which is conducive to the discharge of air bubbles, therefore,it has the greatest MRR in RUECM,which provides a  basis for future researches.