Abstract
Through-mask electrochemical machining has been shown to be very feasible for machining metal parts with hole arrays. However, machining a large-area hole array by through-mask electrochemical machining has been challenging. To machine a large-area hole array, in this paper, a serpentine flow channel is proposed for through-mask electrochemical machining. The principle of the serpentine flow channel is introduced. Computational fluid dynamic simulations show that the flow state in the channel is not uniform. To deal with this problem, circular deflectors are placed in the corners of the channel. By adjusting the circular deflectors, an optimal serpentine flow channel is obtained with a steady flow state. This optimal channel is used in a through-mask electrochemical machining experiment, and a 10 × 20 hole array with 2.564-mm average diameter is fabricated. The maximum deviation of diameters is 0.04 mm, and the roundness is less than 8 μm in this hole array.
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