Abstract: A new machining approach was proposed using electrolyte film to support the floating cathodes to form the machining inter-electrode gaps, whose regulation and control were realized by adjusting the flows and currents. Taking ECM of floating cathodes with round mouths as an example, a mathematic model of the machining gaps was established on the basis of fluid mechanics and electrode process kinetic theory, and the relationships among gaps, flows, pressure differences and currents were acquired. By analyzing characteristics of the gap flow fields using the software Fluent, the distributions of pressure fields and velocity fields of the electrolyte in the gaps were established, and pressure differences between the inlets and outlets, and the flow rates of the outlets were obtained. Additionally, different machining gaps under dissimilar flow and current circumstances were acquired by experiments. The results and variation characteristics of the theoretical model and the experiments are similar to each other.

Key words: electrochemical machining(ECM), inter-electrode gap, floating cathode, electrolyte

摘要： 提出利用极间电解液液膜支撑阴极悬浮形成加工间隙，通过调节流量和电流实现极间间隙的调节和控制的新方法。以圆形出液口悬浮阴极平面电化学加工为例，基于流体力学和电极过程动力学理论建立加工间隙的数学模型，得到间隙与流量、压差及电流之间的关系。利用Fluent软件对间隙模型流场特性进行分析，得到间隙中电解液的压力场和速度场的分布情况，进而得到进出口压差和出口流速；实验获得不同流量、电流条件下的加工间隙。理论模型计算结果和实验数据结果相近，变化规律基本一致。

关键词: 电化学加工, 极间间隙, 悬浮阴极, 电解液