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<p>The inverted T-slot structure plays a crucial role in the medical field; however, its precision machining remains a significant challenge. To address this, an efficient electrochemical milling method based on a specialized hollow shaped-electrode is proposed in this paper. First, a fluid field simulation model was established to analyze the electrolyte flow distribution within the inter-electrode gap, guiding the design and fabrication of the custom hollow electrode. Subsequently, the influence of various processing parameters on the dimensional accuracy of the inverted T-slot was systematically investigated through both simulation and experimental validation. The experimental results demonstrate that under the optimized parameters—an electrolyte pressure of 0.9 <i>MPa</i>, a voltage of 12 <i>V</i>, a frequency of 1 <i>KHz</i>, a pulse duty cycle of 40%, and a feed rate of 0.6 <i>mm/min</i>—an inverted T-slot with an average width of 8.60 ± 0.08 <i>mm</i>, an average height of 3.542 ± 0.06 <i>mm</i>, and a depth of 10 <i>mm</i> was successfully fabricated using a single-pass milling process.</p>

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Research on electrochemical milling technology for inverted T-shaped slot groove structures

  • 期刊论文

  • 发表日期：

    2026年8月3日

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  • Fan Du,
  • Lifeng Zhang,
  • Yujie Zhang,
  • Hua Chen,
  • Kai Cheng,
  • Guokang Su,
  • Congmin Zhu,
  • Chuanyun Zhang

摘要

The inverted T-slot structure plays a crucial role in the medical field; however, its precision machining remains a significant challenge. To address this, an efficient electrochemical milling method based on a specialized hollow shaped-electrode is proposed in this paper. First, a fluid field simulation model was established to analyze the electrolyte flow distribution within the inter-electrode gap, guiding the design and fabrication of the custom hollow electrode. Subsequently, the influence of various processing parameters on the dimensional accuracy of the inverted T-slot was systematically investigated through both simulation and experimental validation. The experimental results demonstrate that under the optimized parameters—an electrolyte pressure of 0.9 MPa, a voltage of 12 V, a frequency of 1 KHz, a pulse duty cycle of 40%, and a feed rate of 0.6 mm/min—an inverted T-slot with an average width of 8.60 ± 0.08 mm, an average height of 3.542 ± 0.06 mm, and a depth of 10 mm was successfully fabricated using a single-pass milling process.