Electrolyte jet machining (EJM) is an innovative form of electrochemical machining (ECM) with excellent machining flexibility and accuracy. Recently, the nozzle inclination is introduced into EJM to further expand its machinability. In this work, to clearly reveal the mechanism behind this EJM process, a three-dimensional (3-D) multiphysics model of the stationary EJM process accounting for two-phase flow field and electric field was developed for the first time and experiments were also performed for validation. With the inclined nozzle, the distribution of flow velocity and thickness of electrolyte film around the jet exhibits uneven, thus resulting in non-circular hydraulic jump and non-axisymmetric anodic current density distribution, respectively. Besides, the effects of nozzle inclination angle and electrolyte ejecting flow velocity were investigated. Larger inclination angle leads to increased asymmetry of flow velocity and current density distribution, which results in more seriously non-circular hydraulic jump and asymmetric machined dimple shape. The electrolyte ejecting flow velocity affects the jet shape and current density distribution that eventually influences the machined results with the inclined nozzle, but this effect does not exist with the conventional vertical nozzle. Moreover, this work was extended to the translating EJM process to study the effect of nozzle translating direction with the inclined nozzle. It is demonstrated that through selecting translating directions, grooves with different shapes and surface finish can be machined even using a certain nozzle inclination. The mechanism for these phenomena was clarified by simulation, paving the way for design of the EJM process with the inclined nozzle.

电解液喷射加工 (EJM) 是电化学加工 (ECM) 的一种创新形式，具有出色的加工灵活性和精度。最近，喷嘴倾角被引入 EJM 以进一步扩展其可加工性。在这项工作中，为了清楚地揭示这种 EJM 过程背后的机制，首次开发了考虑两相流场和电场的稳态 EJM 过程的三维 (3-D) 多物理场模型，并进行了实验。进行验证。采用倾斜喷嘴时，射流周围的流速和电解质膜厚度分布不均匀，从而分别导致非圆形水跃和非轴对称阳极电流密度分布。除了，研究了喷嘴倾角和电解液喷射流速的影响。较大的倾角导致流速和电流密度分布的不对称性增加，从而导致更严重的非圆形水跃和不对称加工凹坑形状。电解液喷射流速影响射流形状和电流密度分布，最终影响倾斜喷嘴的加工结果，但传统的垂直喷嘴不存在这种影响。此外，这项工作扩展到平移 EJM 过程，以研究喷嘴平移方向与倾斜喷嘴的影响。结果表明，通过选择平移方向，即使使用一定的喷嘴倾角，也可以加工出不同形状和表面光洁度的凹槽。