Enhancement of surface quality in the electrochemical milling of 316L using a novel cathode structure

Abstract

In electrochemical jet milling (EJM), enhancing the current density at the trail edge of a workpiece can improve the surface quality. In this study, a novel rectangular cathode tool structure insulated at one side was designed to reinforce the current density at the trail edge of a workpiece to improve the machined surface quality. Numerical simulation was performed to analyse the current density distribution with respect to various parameters, and experiments were conducted to verify the simulation results. The simulation results showed that the current density could be strengthened by utilising the tool with an insulated frontal nozzle tip, which can improve the surface quality during the machining process. Meanwhile, the experimental results revealed that a mirror-like surface could be obtained when utilising the tool under favourable conditions. Compared to other tools, the surface machined by the tool with an insulated frontal nozzle tip had minimum roughness, defects, and overcut.