Flow field analysis in electrochemical machining of non-uniform grooves on the inner surface of a tube

In order to improve the machining quality of the inner surface of non-uniform grooves, this study used ECM to complete the processing of special-shaped grooves. And the flow field distribution during the ECM process of non-uniform grooves on the inner surface of the tube was analyzed by simulation software. The simulation results show that the electrolyte is evenly distributed in the processing gap, and there is no cavitation, and the flow rate of the electrolyte gradually increases with the decrease of the machining gap. ECM experiments were carried out under different process parameters. The experimental results show that the average surface roughness of the workpiece processed by ECM technology is about 0.7, which is 89% lower than that of the traditional surface roughness, and the shape accuracy meets the requirements. Under the same test conditions, the average depth of the groove increased by 0.55 mm and the average width increased by 0.6 mm for every 2 V increase of voltage, and the average depth increased by 0.2 and width increased by 0.25 for every 0.2 MPa increase in pressure. This study clarifies the processing process of non-uniform grooves by ECM technology, and provides an important theoretical basis for the processing of weapon devices.