Simulation and Experimental Study on Micro Electrochemical Drilling with ultra Short Pulse Voltage by using High-speed Spiral Electrode

摘要

Background: The fabrication of Micro-holes in hard machining materials is always difficultaccording to recent patents. The electrochemical drilling process is a good selection for the fabricationof Micro-holes.Methods: In this paper, an electrochemical drilling process for fabricating Micro-holes with high efficiency isintroduced, and simulation of the gap electric field and the gap flow field is carried out. Firstly, the model of ultrashort pulse gap electric field is established, the shape change of the anode workpiece surface in the electricfield is analyzed and predicted based on the simulation of the drilling with ultra short pulse voltage. Then, thenumerical simulation of the gap flow field is simulated by CFX with the increase of the electrode rotatingspeed. Finally, the simulation results are verified by the experiments.Results: The removal direction and rate of a point on the surface of the workpiece with ultra short pulsevoltage was derived. The shape change of the anode workpiece surface with ultra short pulse voltagewas simulated. The distribution of water vapor and the velocity vector graph in micro machining wasobtained. A series of Micro-holes was machined successfully, the diameter of the Micro-holes was lessthan 200µm.Conclusion: The ultra short pulse voltage can greatly improve the machining localization. The gas filmwith good insulation effect around the electrode increases rapidly, which can reduce the taper of the Micro-holes significantly. The experiment results prove that the micro electrochemical drilling for fabricatingMicro-holes has a huge potential and a widespread application prospect.