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<p>Stray corrosion is a significant challenge in electrochemical machining (ECM), typically occurring on non-machining surfaces due to mass-transfer reactions between the tool electrode and these surfaces. The use of tube electrodes, common in ECM, often results in the central portion of microstructures exhibiting a convex structure. In response to these challenges, an integrated tool cathode with synchronous liquid supply has been developed, offering a 360° liquid supply mode to enhance the uniformity of lateral fluid supply. Unlike tube electrodes, this electrode features a solid structure, effectively eliminating the convex structure issue. Control over the machining area is achieved through cooperative adjustments of electrolyte outlet size and pressure to eliminate stray corrosion. Comprehensive simulations of flow fields, electric fields, and anodic erosion using COMSOL Multi-physics software ensure the rationality of the electrode structure. The verification experiments conducted on a 304 stainless steel sheet validate the effectiveness of the integrated tool electrode in addressing several key issues, including stray corrosion, residual convex, and uneven liquid supply. This study holds significant implications for advancing the engineering application of micro-structures.</p>

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Improvement of surface defects in ECM using an integrated tool electrode with synchronous liquid supply

  • 期刊论文

  • 发表日期：

    2025年2月16日

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  • Haihong Ai,
  • Kun Wang,
  • Shuoqi Lv,
  • Ravi P. Singh,
  • Zhanshan Wang

摘要

Stray corrosion is a significant challenge in electrochemical machining (ECM), typically occurring on non-machining surfaces due to mass-transfer reactions between the tool electrode and these surfaces. The use of tube electrodes, common in ECM, often results in the central portion of microstructures exhibiting a convex structure. In response to these challenges, an integrated tool cathode with synchronous liquid supply has been developed, offering a 360° liquid supply mode to enhance the uniformity of lateral fluid supply. Unlike tube electrodes, this electrode features a solid structure, effectively eliminating the convex structure issue. Control over the machining area is achieved through cooperative adjustments of electrolyte outlet size and pressure to eliminate stray corrosion. Comprehensive simulations of flow fields, electric fields, and anodic erosion using COMSOL Multi-physics software ensure the rationality of the electrode structure. The verification experiments conducted on a 304 stainless steel sheet validate the effectiveness of the integrated tool electrode in addressing several key issues, including stray corrosion, residual convex, and uneven liquid supply. This study holds significant implications for advancing the engineering application of micro-structures.