Improvement of machining consistency during through-mask electrochemical large-area machining

• DOI: 10.1016/j.cja.2018.06.006
• Publication Date: 2018-06-21T01:54:38Z
• Authors: Guoqian WANG; Hansong LI; Chao ZHANG; Di ZHU
• Keywords: 0203 mechanical engineering; 02 engineering and technology; 3. Good health

Abstract Electrochemical machining (ECM) is an important machining technique for the aeronautical manufacturing industry. Through-mask ECM is a form of ECM for machining metal parts with a hole array. In order to extend the machining area, a serpentine flow channel with multiple curves was used for through-mask ECM. With the extension of the flow channel, ensuring a machining consistency along the flow channel has been a challenge. The electrolyte conductivity is the main factor affecting the machining consistency. To analyze the change rules of the electrolyte conductivity, variations in the bubble rate and the temperature of the electrolyte in the electrolyte flow were explored under different power sources. Results indicate that pulse-power machining can reduce variations in the bubble rate and the temperature in the serpentine flow channel, and then the electrolyte conductivity can be stabilized within a very small range. Experiments using through-mask ECM were conducted in two types of power sources. Experimental results support the importance of pulse-power machining. A 14 × 28 hole array with a 2.5 mm diameter was fabricated by a pulsed power source. The aperture deviation of the hole array is less than 0.05 mm, and the roundness deviation is less than 15 μm when fabricated with pulse machining.