In this paper, the forming mechanism of cooling hole electrolytic machining is studied using multi-physical field coupled simulation and experimental observation. A multi-physical field coupled simulation model was established to obtain the gas-liquid two-phase distribution law inside the machining gap, and a mathematical model of gas-liquid two-phase flow was established to analyze the change law of the size and morphology of cooling hole electrolytic machining under different process parameter conditions. The simulation and experimental results show that the size of the inlet of the cooling hole is larger, the size of the outlet is smaller, and the middle section is more stable; machining voltage and electrode feed speed have a significant influence on the size and shape of heat dissipation holes. Compared with the experimental data, simulation accuracy is good.
Keywords: electrochemical machining; feed rate; gas–liquid two-phase flow; multi-physical field coupling simulation; processing voltage.