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<p>Electrolyte jet machining (EJM) offers several advantages, including high flexibility, zero cutting force, and no tool wear. In the process of research, the material removal rate (MRR) has been paid more and more attention by researchers. The MRR serves as a crucial technical metric in EJM, with the anode surface current density playing a pivotal role in its determination. Within a specific range, the trailing current density on the anode workpiece surface often remains low because the rear end face of the cathode tool does not contact the electrolyte. To enhance this trailing current density, this study proposes a stepped tool design featuring a downward-shifted rear end face of the cathode tool. Numerical simulations demonstrate that the stepped tool can ensure contact of the rear end face with the electrolytic liquid phase, enhance the electrolyte flow rate in the machining gap, and substantially increase the trailing current density. Experimental findings validate these simulations, showing a 68.18% increase in machining current and a 96.23% rise in MRR using a tool with a 0.7&#xa0;mm downward shift compared to a conventional tool. Further investigation into deeper undercutting (1.3&#xa0;mm) reveals even more significant improvements, with a machining current increase of 113.64% and an MRR increase of 176.06% over conventional methods. Moreover, groove depth increased by 151.06%, and the groove taper angle was&#xa0;measured&#xa0;at 62.62°. These results clearly demonstrate the effectiveness of the proposed tool modification in improving the&#xa0;MRR of EJM.</p>

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Improving material removal rate in electrolyte jet machining using stepped cathode tool

  • 期刊论文

  • 发表日期：

    2025年2月17日

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  • Jiajie Chen,
  • Qingqing Wang,
  • Ningsong Qu,
  • Hansong Li

摘要

Electrolyte jet machining (EJM) offers several advantages, including high flexibility, zero cutting force, and no tool wear. In the process of research, the material removal rate (MRR) has been paid more and more attention by researchers. The MRR serves as a crucial technical metric in EJM, with the anode surface current density playing a pivotal role in its determination. Within a specific range, the trailing current density on the anode workpiece surface often remains low because the rear end face of the cathode tool does not contact the electrolyte. To enhance this trailing current density, this study proposes a stepped tool design featuring a downward-shifted rear end face of the cathode tool. Numerical simulations demonstrate that the stepped tool can ensure contact of the rear end face with the electrolytic liquid phase, enhance the electrolyte flow rate in the machining gap, and substantially increase the trailing current density. Experimental findings validate these simulations, showing a 68.18% increase in machining current and a 96.23% rise in MRR using a tool with a 0.7 mm downward shift compared to a conventional tool. Further investigation into deeper undercutting (1.3 mm) reveals even more significant improvements, with a machining current increase of 113.64% and an MRR increase of 176.06% over conventional methods. Moreover, groove depth increased by 151.06%, and the groove taper angle was measured at 62.62°. These results clearly demonstrate the effectiveness of the proposed tool modification in improving the MRR of EJM.