Electrochemical machining of array microgrooves using optimized shaped sheet cathodes

Abstract

ABSTRACT Shaped cathode electrochemical machining is often used to process array microgrooves on difficult-to-machine materials because of its great flexibility. Unlike the single-groove structure, the current density distribution varies greatly during machining of array microgrooves, which is mainly dependent on the sheet cathode array offset (SCAO). This study establishes and validates a mathematical model based on SCAO for the stray-current density, U, and ton. Then the end gap and side gap are modeled. Next, through simulation, the current density distribution at various SCAO is examined. It has been discovered that when the SCAO grows, the current density distribution becomes more uniform, and the stray-current density becomes milder. The array microgrooves having high quality and high density can be fabricated at a SCAO of 1.4 mm. Additionally, the experiments show that quality and efficiency can be ensured under the optimal parameters.