Simulation of the influence of the tool electrode vibrating with dual ultrasonic frequency in ECM

Abstract

In electrochemical machining (ECM) of deep narrow grooves, it can be effectively solved the problem of difficult by-product discharge through applying ultrasonic vibration to the tool electrode. However, the vibration application will affect the distribution of bubble in the processing area, which may cause the machining groove width become uneven. To solve this problem, a method of dual-frequency transverse ultrasonic-assisted electrochemical machining to change the vibration frequency intermittently was proposed. In this paper, the influence of the vibrating tool electrode on ECM characteristics under dual ultrasonic frequency is analyzed by COMSOL Multiphysics. The results show that the distribution of bubble and flow velocity in the machining area is similar to ultrasonic vibration transformation under dual-frequency ultrasonic vibration, which can improve the efficiency of processing and solves the problem of uneven section under single ultrasonic frequency.