為節省加工之時間成本，本論文探討使用COMSOL Multiphysics多重物理場耦合軟體應用在預測電化學鑽孔技術之模擬，其中除考慮電場影響外，也加入氣泡對流場的影響。實驗電極採用直徑500 μm之中空黃銅管，加工工件為304不鏽鋼材料，過程中採定電壓加工方式，搭配電解混氣裝置以進行實驗。透過調整不同加工電壓、進給速度、混氣電流，進行12mm淺孔加工實驗。基於淺孔加工結果，加入液體流速之修正係數，進行淺孔模擬線性擬合，並將模擬模型用於預測深孔加工結果，嘗試預測深孔出口之孔徑與極限加工深度，並與實驗結果進行比對，最終完成深徑比為86之深孔加工與一深孔加工模型，未來可透過此模型預測深孔加工出結果，以減少時間成本。 結合實驗與模擬結果顯示，無混氣之深孔加工可加工至深度61mm，混氣電流為0.25A時，加工深度可至95mm，透過淺孔擬合之模型嘗試預測深孔孔徑之誤差隨深度增加而逐漸增加，其中加工深度95mm時，加工孔徑與模擬之誤差為9.4%。 ;To reduce the time cost of machining, this study explores the application of COMSOL Multiphysics, a multiphysics coupling software, for simulating the prediction of electrochemical drilling technology. In addition to considering the influence of the electric field, the study also incorporates the effect of bubble convection on the flow field. The experimental electrode used is a hollow brass tube with a diameter of 500 μm, and the workpiece material is 304 stainless steel. The machining process adopts a constant voltage method, combined with an electrolyte gas-mixing device for experimentation. Shallow hole machining experiments with a depth of 12 mm were conducted by adjusting different machining voltages, feed rates, and gas-mixing currents.Based on the shallow hole machining results, a correction coefficient for the liquid flow rate was introduced to perform linear fitting for shallow hole simulations. The simulation model was then applied to predict deep hole machining results, attempting to estimate the bore diameter at the deep hole outlet and the maximum machining depth. These predictions were compared with experimental results, ultimately achieving deep hole machining with an aspect ratio of 86 and developing a deep hole machining model. In the future, this model can be used to predict deep hole machining outcomes and reduce time costs. The combination of experimental and simulation results indicates that deep hole machining without gas mixing can reach a depth of 61 mm. When the gas-mixing current is 0.25 A, the machining depth can reach 95 mm. The error between the predicted and experimental bore diameters increases with depth; at a machining depth of 95 mm, the error between the experimental and simulated bore diameter is 9.4%.
