Experimental research on process stability in pulsed electrochemical machining of deep narrow grooves with high length-width ratio

With respect to deep narrow groove structures with high length-width ratio and high depth-width ratio (particularly when the ratio is greater than 10), the cathode rigidity and flow-field stability deteriorate during the electrochemical machining (ECM) process. To improve the machining efficiency and process stability of deep narrow grooves with high length-width ratio, a hollow slice cathode with stiffeners was designed and optimized to meet the rigid requirements using the method of one-way fluid-solid coupling finite element analysis. Additionally, the effects of cathode stiffener size, stiffener distribution, and cathode vibrating feed mode on the flow field in the machining gap were investigated using the flow-field simulation analysis method. The simulation results indicate that cavitation and electrolyte starvation in the machining gap are avoided with a reasonable stiffener design, and the renewal of electrolyte in the machining gap is improved with a reasonable vibration motion. Contrast experiments were performed based on the simulation results. The experimental results verified that the optimal design of stiffeners and the reasonable cathode vibration improve the stability of the flow field. Moreover, process stability and machining efficiency of ECM of deep narrow grooves with high length-width ratio improve with the adoption of the optimal vibrating feed parameters.