Experimental Research on Improving ECM Accuracy and Stability for Diamond-hole Grilles

Abstract

The demand for high-quality diamond-hole grilles, characterized by a voluminous and closely spaced array distribution of holes, has stretched traditional machining to the limit. For this reason, electrochemical machining is considered to be one of the better processing technologies for diamond grid holes. In order to improve the accuracy of electrochemical machining (ECM) for diamond-hole grilles, factors affecting the ECM process based on the electrochemical anodic dissolution theory were investigated in this study. The importance of small-gap processing for achieving higher machining accuracy was highlighted. In small-gap processing of diamond holes, the ECM mode was optimized using cathode side insulation, pulse power supply, passivating electrolyte, and other measures. A test-based comparative analysis of two differing machining modes, i.e., composite-feed ECM mode and precise ECM mode, was performed. The results showed that precise ECM mode, which precisely synchronizes the composite feed vibration with the pulse power supply, offered better machining accuracy and process stability in the ECM process for diamond-hole grilles. Precise ECM mode is envisaged to play a prominent role in the development of ECM technology.