Cathode structure optimization and process experiment in electrochemical machining of multi-stage internal cone hole

In order to solve the problem of uneven gap distribution and flow pattern in complex parts with multi-stage internal cone hole electrochemical machining, a method computer simulation–assisted cathode design is proposed. The electric field models machining are established respectively, simulations different profiles carried out. When angle 2°, between workpiece reasonable, electrolyte uniform. With conditions processing voltage 10 V, inlet pressure 1.5 MPa, temperature 28 ℃, feed speed 5 mm/min, (ECM) out by using optimized cathode. results show that surface has no pattern, dimensional forming accuracy better than 0.1 mm, roughness reaches Ra 0.697 μm. Research shows optimization structure simulation can shorten development cycle reduce cost effectively ECM, which provides an efficient feasible for structure.