Simulation of Electric Field Distribution by Cathode Geometry and Insulator Height

During electrolytic machining, the electrolyte current density has a significant effect on process stability, machining efficiency, and workpiece surface quality. In this study, we utilized simulation software (COMSOL) to investigate the impact of different cathode profiles, cathode insulation layer height, and processing voltage on the surface current density of the workpiece through electric field analysis. The simulation results indicate that the appropriate cathode profile enhances the stability and uniformity of the electrolyte current density. Optimizing the cathode insulating layer height further improves the uniformity of the electrolyte current density of the outer profile to meet the requirements of uniformity and stability. As the machining voltage increases, the current density also increases, but the uniformity of the processing voltage decreases. To meet the machining requirements, a higher machining voltage should be selected.