目的 以电解加工的方法去除多余的焊层，避免人工打磨引起焊接表面的二次损伤。方法 以哈氏合金X为母材，经TIG焊后，对焊缝进行电解加工去除的仿真及试验研究。分别建立三维、二维的仿真模型，分析加工区域的电场、流场及产热功耗的分布以及焊层轮廓形貌随时间的变化。通过正交试验，选取适当的去除焊层电解加工工艺参数，将模拟仿真的结果与试验结果进行对比，分析焊层去除过程中理论值与实测值偏差的原因。结果 通过模拟仿真计算可以发现，在电解加工模型中，电场、温度场以及流场耦合作用下，焊缝中心的蚀除速率明显低于焊缝两端，且随加工时间的延长，蚀除沟的形貌越来越明显，二维模型可以精准地表征加工间隙内阳极表面电解速率的变化。基于正交试验发现，电解加工的电压和频率对焊层去除量影响显著，占空比影响不大。加工电压为30 V时，表面平均粗糙度最小，为19.2 μm，去除量为0.241 g。结论 焊层去除后的轮廓形貌与仿真计算结果趋势一致，可准确地表征电解加工方法去除镍基合金焊层的过程，能够实现仿真模拟与工艺试验的相互优化。

The study aims to remove the excess welding layer by electrochemical machining to avoid secondary damage on the welding surface caused by manual grinding. Through the simulation and experimental study on the removal of the weld joints after TIG with Hastelloy-X as base metal. The three-dimensional and two-dimensional simulation models are established to analyze the distribution of electric field, flow field and heat generation power consumption in the processing area, as well as the change of welding layer profile with processing time. The proper electrochemical machining parameters for removing welding layer were selected by orthogonal test. The results of simulation and experiment are compared to analyze the reasons for the deviation between theoretical value and measured value in the process of removing welding layer. The simulation results show that the erosion removal rate of the weld center is significantly lower than that of the two ends of the weld joints under the coupling of electric field, temperature field and flow field, and the morphology of the erosion removal groove becomes more obvious with the increase of processing time; The two-dimensional model can accurately characterize the change of electrolyte rate on anode surface in machining clearance. Based on the orthogonal test, it is found that the voltage and frequency of electrochemical machining have a significant effect on the removal of welding layer, and the duty ratio has little effect. When the processing voltage is 30 V, the average surface roughness reaches a minimum of 19.2 μm, and the removal amount is 0.241 g. The profile morphology after the removal of the welding layer is consistent with the trend of the simulation results, which can accurately characterize the process of removing the Ni-based alloy welding layer by electrolytic machining method, and can realize the mutual optimization of simulation and experiment.