中文摘要：

基于建立的三维多相流模型及间接耦合多物理模型（热电耦合和热流耦合）,以螺旋孔电解加工为研究对象,对电解加工间隙中的电场、流场、温度场进行分析,掌握间隙参数变化规律,包括间隙电解液的流速与温度、间隙氢气气泡率分布、材料表面电流密度分布等.进而对影响材料去除的主要因素——电导率进行研究,确定了电导率在整个加工间隙内的变化规律及其对材料去除的影响,并提出了增加电解液出口背压以改善工件材料去除的一致性.最后,在搭建的实验平台上进行螺旋孔电解加工实验,验证了所提方法的正确性.

英文摘要：

The three-dimensional multiphase flow model and indirect multiphysics model （including thermoelectric coupling model and thermal-fluid coupling model） are developed to describe the variations of electric field,flow field and temperature in the electrochemical machining gap.The electrochemical machining of the internal spiral hole is simulated.Simulation results show that the electrolyte velocity is fluctuant and decreasing,and the electrolyte temperature as well as the void fraction of the hydrogen are increasing along the flow direction.According to the variations of temperature and the void fraction of hydrogen,the electric conductivity of electrolyte is studied,which has a main effect on the material removal.The analysis denotes that the electric conductivity of electrolyte increases along the flow direction.As a result,the material removal rate （MRR） decreases along the flow direction which is unfavourable for machining.A method of applying back pressure in the outlet is selected to diminish the variation of electric conductivity of the electrolyte.Finally,experimental verification of the model using an in-house built electrochemical machining system for the internal spiral hole exhibits good correlation with theoretical predictions.