Simulation Research of Small Holes by Combined Ultrasonic and Electrochemical Machining Based on CFX

A device was designed to study the small holes by the rotary combined ultrasonic and electrochemical machining, and the gap between cathode and anode in the processing was also analyzed. A three-dimensional model of flow field was developed in ANSYS CFX software based on FEM by the gas-liquid two-phase fluid cavitations model as well as the effect of rotary cathode and the vibrated cathode to the flow field was analyzed. The simulation showed that the pressure and the velocity of the electrolyte in the gap were oscillated by additional motion of cathode, which is helpful to the electrochemical machining. The comparison of rotary electrochemical machining and the rotary combined ultrasonic and electrochemical machining showed that the rotary combined ultrasonic and electrochemical machining has better ability of making small holes than that of rotary electrochemical machining