Flow field distribution plays a vital role in electrochemical machining (ECM) because it can directly affect the machining stability and accuracy of ECM. In counter-rotating electrochemical machining (CRECM), the uniformity of the flow field is difficult to control due to the complicated and changeable flow channel shape. Through the simulation of the conventional lateral fluid flow pattern, it is found that the complexity of the flow channel with grid structures makes the flow field of machining area strongly disordered, which leads to the low velocity zones and dead zones. Based on the simulation results, a new electrolyte flow pattern with an auxiliary internal fluid is proposed, which can remarkably improve the uniformity of flow field by apply supplementary electrolyte to the machining area. Experimental results show that the new flow pattern effectively improves the machining stability of CRECM, and enhances the machining precision of grid structures, the sidewall taper angle is reduced from 29.3° to 7.7°.

流场分布在电化学加工 (ECM) 中起着至关重要的作用，因为它可以直接影响 ECM 的加工稳定性和精度。在反向旋转电化学加工（CRECM）中，由于流道形状复杂多变，流场的均匀性难以控制。通过对常规横向流体流型的模拟发现，网格结构流道的复杂性使得加工区域的流场强烈无序，从而导致低速区和死区。基于模拟结果，提出了一种具有辅助内部流体的新电解液流动模式，通过在加工区域添加补充电解液，可以显着提高流场的均匀性。