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Research on Electrochemical Machining with Synchronization of Pulse Current and Low-frequency Vibration

As a method of precision electrochemical machining, the principle of pulse and vibration synchronized electrochemical machining is complex. In this work, a multi physical field coupling model of pulse and vibration synchronized electrochemical machining including electric field, gas-liquid two-phase flow field and temperature field was established. The changes of electrolyte temperature, electrolyte flow velocity, bubble volume fraction and electrolyte conductivity in end gap with vibration period were analyzed. In addition, the experiment was carried out on the precision electrochemical machining equipment with the same process parameters as the simulation parameters, and the workpiece with taper of 0.9º, end surface roughness of 0.134 µm and side surface roughness of 0.586 µm was machined. The pulse and vibration synchronized electrochemical machining can improve machining accuracy and machining quality. The research results have important guiding significance for practical machining.