Electrochemical machining of multiple slots with low-frequency tool vibrations

In electrochemical machining (ECM) of multiple slots, the electrolytic flow field distribution is a critical factor to the process stability, which may draw unwanted abnormal phenomena such as short-circuits. Using finite element method, the flow field distribution in ordinary ECM method of multiple slots was calculated. The simulation results revealed that most of the electrolyte will drain away from the channels between cathode tools. The electrolyte velocity in the machining gap will be reduced and hardly remove the electrolytic products in time. This paper suggested a method for ECM of multiple slots with low-frequency tool vibrations to improve the electrolyte velocities in machining gaps. Tool vibration will improve the refresh of electrolyte in the machining gap and promote the removal rate of electrolytic products. For higher electrolyte velocities, the relationship between section area ratio (SAR) and electrolyte velocities was discussed. The optimized tools height with best SAR was suggested. Experiments were carried out to evaluate the process stability of the ordinary and suggest method. The results verified that electrolyte velocities were improved significantly with low-frequency tool vibrations and promoting SAR. A specimen with 30 slots was fabricated in ECM with low frequency tool vibrations and optimized tools height. (C) 2016 The Authors. Published by Elsevier B.V.