ABSTRACT Counter-rotating electrochemical machining (CRECM) holds the unique advantages to machine thin-walled revolving parts, especially for thin-walled engine cases. The electric field intensity distribution on the revolving anode surface is non-uniform, which is difficult to calculate accurately. In this work, a novel equivalent model for analytic solution of the electric field in CRECM is proposed based on complex variable function, and anode material dissolution model is established for CRECM. The variations of the material removal rate (MRR) and interelectrode gap (IEG) at different machining parameters have been fully investigated. The results indicate the MRR can reach a relative equilibrium state after a transition stage. The relative equilibrium MRR is higher than the feed rate, leading to a linear increase in the IEG. Moreover, machining parameters are optimized numerically to shorten the time reaching the relative equilibrium state. Experiments are conducted to verify the theoretical results. The experimental results fit well with the theoretical values. It means that the proposed model is effective for the prediction of the material dissolution process in CRECM.

中文翻译：

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反向旋转电化学加工中极间间隙的建模与实验验证

摘要 反向旋转电化学加工 (CRECM) 在加工薄壁旋转零件方面具有独特的优势，特别是对于薄壁发动机箱。旋转阳极表面的电场强度分布不均匀，难以准确计算。在这项工作中，提出了一种新的基于复变函数的 CRECM 电场解析解等效模型，并建立了 CRECM 的负极材料溶解模型。已经充分研究了不同加工参数下材料去除率 (MRR) 和极间间隙 (IEG) 的变化。结果表明 MRR 在过渡阶段后可以达到相对平衡状态。相对平衡 MRR 高于进料速率，导致 IEG 线性增加。而且，对加工参数进行数值优化，缩短达到相对平衡状态的时间。进行实验以验证理论结果。实验结果与理论值吻合良好。这意味着所提出的模型对于预测 CREC 中的材料溶解过程是有效的。