Improving flatness of machined surface in rotating cathode electrochemical milling

Electrochemical milling has broad application prospects for machining large aeronautical thin-walled components. This is because this technique has no cutting force, has no heat-affected zones, and is considerably flexible. In contrast to the non-rotating tool cathode of traditional electrochemical milling, the rotating cathode used in electrochemical milling has more promising prospects because it has the same motion mode as the milling cutter employed in mechanical milling. However, because of the uneven electric quantity supply from the cylindrical rotating cathode, the machined surface typically has a curved profile with inadequate surface flatness; this is the main drawback of rotating-cathode electrochemical milling. To improve the flatness of surfaces processed by rotating-cathode electrochemical milling, a novel multichannel cathode with the outlet hole arrangement that can improve the uniformity of electric quantity supply is proposed. Numerous large outlet holes are bored at the bottom center of multichannel rotating cathode. Numerical simulation results indicate that these holes cause a decrease in the electric quantity supply from the inner area at the bottom of the cathode from the perspectives of electric and flow fields, minimizing the unevenness of the electric quantity supply distribution. Validation experiments prove that compared with previously reported rotating cathodes, the straightness index and depth error of the surface machined by novel multichannel cathode are reduced by 80.9 % and 69.4 %, respectively. After obtaining grooves with flat surfaces, the step-over distance required to machine a plane using a multichannel rotating cathode increases; meanwhile, the flatness of the machined plane significantly improves. With the applied voltage of 25 V, electrolyte pressure of 0.2 MPa, initial inter-electrode gap of 0.2 mm, and cathode rotational speed of 500 rpm, a 42 x 40 mm plane is finally machined, whose planeness index (Delta hp) is only 0.047.