Multi-Physics Field Coupling Simulation Analysis And Process Parameter Optimization of ECM Hole-Making Process For Superalloys

Electrochemical processing is crucial for manufacturing cooling holes in nickel-based superalloy films. However, due to the complex interactions among process parameters, optimizing process parameters such as voltage, feed rate, and electrolyte conductivity remains challenging. In this paper, a multi-physics field model coupling the electric field and the flow field is established. The electric field distribution and workpiece deformation during the electrochemical machining process are analyzed, and the gas-liquid two-phase flow model is adopted to simulate the electric field, flow field and current density. Then, by using the central composite design method, the regression equations of the average aperture, average taper and process parameters, as well as the interaction laws of single and multiple factors, were derived. When the diameters are 0.5mm, 0.6mm and 0.7mm, the predicted corresponding optimal parameter combinations are voltages of 30V, 42.2V and 53.8V respectively, the electrical conductivity was 8.7 S/m, 8.7 S/m, 11.4 S/m and the feed rates were 0.46 mm/min, 0.46 mm/min, 0.49 mm/min. Finally, the experiments verified that the maximum errors of diameter and taper were 7.6% and 6.43% respectively. The experimental results proved the accuracy of the model. This work has greatly improved the accuracy of electrochemical processing of cooling holes.