Research on Electrochemical Machining Technology of Small-hole Using Suction Electrode

The stray corrosion at the entrance of the electrochemical machining of small-hole in the aero-engine seriously affects the fatigue strength of the parts. Because the morphology of the electrochemical machining entrance is not ideal, the stray corrosion of the micro-hole entrance is reduced by suction electrode processing. In this work, the electric field, flow field distribution, and contour forming process in the electrochemical machining process are analyzed by a multi-physical field model. The simulation results and the experimental results are compared with each other under the same parameters to optimize the processing parameters. The influence of supply flow rate and suction pressure on the inlet morphology is analyzed. The simulation and experimental results show that the region of low current density region at the entrance of suction electrode electrochemical machining can be significantly reduced,which improves the locality of the machining. If the supply flow rate is 1.5 ml/min and the reflow rate is 27 ml/min, the best inlet morphology without stray corrosion will be obtained with stable processing without the short circuit. This work is of great significance for further understanding the principle of electrochemical machining of suction electrodes and improving the quality of small holes in superalloys.