Research on the Characteristics of Forward Flow Electrochemical Machining Coupled with Pulse Current and Cathode Vibration

In pulse‐vibration forward‐flow electrochemical machining, the cathode undergoes vibration, and a pulsed current is applied. This process integrates the advantages of small‐gap electrical machining with large‐gap power‐off flushing. However, it is affected by numerous interacting factors. To investigate these influences, this study employs a coupled simulation of the electric field, gas–liquid two‐phase flow field, temperature field, and structural field. The goal is to analyze changes in hydrogen bubble volume fraction, flow rate, temperature, and conductivity during the machining process induced by pulse vibration. Single‐factor experiments are conducted to assess the impact of various machining parameters. Results show that both machining taper and surface roughness increased with higher machining voltage and longer pulse time. In contrast, these measures decreased with higher feed rates and increased vibration frequency. A multivariate nonlinear regression model is developed using response surface methodology to quantify the significance of each parameter and determine the optimal parameter combination. Under the optimized parameters, the average measured machining taper and surface roughness are 1.09° and 0.332 μm, respectively. The errors between predicted and actual values are 10.1% for machining taper and 7.2% for surface roughness, confirming the model's accuracy and reliability.