Experimental study on immersed rotating cylindrical electrode in electrochemical discharge machining (ECDM)

This study aims to resolve the challenges associated with chip removal and electrolyte renewal during conventional electrical machining of ruled surface structures in difficult-to-machine materials. This study proposes a novel electrochemical discharge machining (ECDM) method utilizing immersion rotating cylindrical electrodes. The proposed method immerses the workpiece in the working medium and uses a rotating cylindrical electrode instead of the conventional wire electrode. A comparative analysis with traditional EDM machining was performed, focusing on the gap current waveform, material removal mechanisms, and surface alteration patterns, followed by a stepped tenon machining verification test. The results show that this method combines spark discharge and electrochemical reactions, thereby improving surface quality and enhancing machining quality and performance. Additionally, the process parameters were optimized by integrating a one-factor experimental regression model with a particle swarm optimization (PSO) algorithm, resulting in efficient machining of stepped tenons.