Abstract
The large complex structure integral components composed of difficult-to-machine material (such as titanium alloy, high temperature alloy) are more and more widely applied in aerospace, weapon equipment and other industries. The material utilization rate and the processing efficiency of the milling process are very low, the cost is high. Micro copper tubes (diameter 2mm, inner diameter 1.6mm) are arranged to electrode with shape to be processed, which could cut these components with a high efficiency and low cost. The fabrication of electrode is simple and convenient, so the cost of electrode could be reduced too. The flow field design is an important problem to be solved. The model of flow field is established, and flow field of different cathodes are simulated．The analysis results show that the rectifying ring is favorable for the electrochemical machining. Finally, the cathode with rectifying ring is used in processing experiment, the edge of cutting zone is orderly, no spark and short circuit occurs. Straight line and circular hole is successfully processed. The feasibility of the scheme is proved.
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