Flow Field Simulation And Experimental Investigation On Macro Electrolyte Jet Electrochemical Turning of TB6 Titanium Alloy

Electrolyte jet electrochemical turning is an effective method to realize high-quality machining of titanium alloy rotating components; however, minimal research has been carried out in this field. This is because it is difficult to control the machining flow field, which leads to poor machining surface quality. In this work, numerical simulations were used to optimize the machining flow field and reduce the proportion of gas that mixed into the machining area. This can promote participation of the tool electrode tip in the electrochemical reaction and improve the machining efficiency. The effectiveness of the optimized machining flow field for jet electrochemical turning was verified experimentally. The results showed that all three kinds of revolving TB6 titanium alloy samples with different structures could maintain the original contour shape, with a contour error <1% and a machined surface roughness reaching Ra 2.414 μm. The results demonstrate the application potential of the jet electrochemical turning process.