Research on the cathode design and experiments of electrochemical machining a closed impeller internal flow channel

In order to improve the electrochemical machining (ECM) precision and efficiency of a closed impeller internal flow channel, the internal flow channel cathode shape and structure were optimized by gap flow field simulation. Firstly, the theoretical model and three-dimensional gap flow field simulation geometric model were set up. Next, the inter-electrode gap flow field simulation results were draw from the streamline, velocity, and pressure cloud picture. Secondly, the cathode and the frock clamp were designed according to the simulation results. Finally, the verification experiment was carried out to evaluate the cathode structure and the ECM process parameters, and the experimental results were consistent with the simulation results. The whole process is stable and no short-circuit phenomenon with the forward flow field machining pattern. The results show that the method of gap flow field simulation-assisted ECM cathode design is useful and economical for machining closed impeller internal flow channel.