Modeling and experimental validation of interelectrode gap in counter-rotating electrochemical machining

Counter-rotating electrochemical machining (CRECM) holds the unique advantages to machine thin-walled revolving parts, especially for thin-walled engine cases. The electric field intensity distribution on the revolving anode surface is non-uniform, which is difficult to calculate accurately. In this work, a novel equivalent model for analytic solution of the electric field in CRECM is proposed based on complex variable function, and anode material dissolution model is established for CRECM. The variations of the material removal rate (MRR) and interelectrode gap (IEG) at different machining parameters have been fully investigated. The results indicate the MRR can reach a relative equilibrium state after a transition stage. The relative equilibrium MRR is higher than the feed rate, leading to a linear increase in the IEG. Moreover, machining parameters are optimized numerically to shorten the time reaching the relative equilibrium state. Experiments are conducted to verify the theoretical results. The experimental results fit well with the theoretical values. It means that the proposed model is effective for the prediction of the material dissolution process in CRECM.