Investigation of the anode shaping process in counter-rotating electrochemical machining of a convex array

Abstract

This paper presents the formation processes of convex arrays on revolving parts by using synchronous and differential counter-rotating electrochemical machining (CRECM) methods, in which cylindrical cathode tools with concave cavities rotate relatively to the anode workpiece at same and multifold rotational speeds. The anode shaping processes are numerically simulated on basis of a mathematical model. The profiles of the convex structures at rotating ratios of 1:1 and 5:1 are compared, and the shape evolution process at different feed depths of cathode tool is analyzed. The simulation results indicate that differential CRECM can achieve an approximate machining performance of a convex array with synchronous CRECM by using suitable diameter of the cathode tool. The profile of the convex structure changes from a tapered shape to an inverted cone shape with the increase of the feed depth of cathode tool. Experiments are conducted to verify the numerical analysis. An equal-size cathode tool with five concave cavities at the same rotation speed and a small cathode tool with a single concave cavity at a rotating ratio of 5:1 are used, respectively. It is seen that five array distributed convex structures are machined successfully on the anode surface by using both synchronous and differential CRECM methods. Furthermore, convex structures with tapered, straight and inverted conical sidewalls can be obtained by changing the depths of cathode tool in differential CRECM.