Simulation and Experimental Study on Improving Electrochemical Machining Stability of Highly Convex Structures on Casing Surfaces Using Backwater Pressure

Abstract Casing parts are regarded as key components of aero-engines. Most casing attached to convex structures different shapes, whose heights range from hundreds microns tens millimeters. Using profiling blocky electrodes for electrochemical machining (ECM) is a commonly adopted method, especially when highly structures. However, with an increase in the structure height, flow fields areas become more complex, and short circuits may occur at any time. In this study, method improve field characteristics within area by adjusting backwater pressure proposed validated through simulation experiment analyses. The results demonstrated that back-pressure can significantly uniformity around compared extraction open outlet modes. Subsequently, value was optimized 0.5 MPa according results. experimental showed using parameters, cathode feed-rate increased 0.6 0.7 mm/min, 16.1 mm tall successfully machined. This indicates suitable effective electrodes. we propose stability on surface pressure, which has achieved remarkable