Optimizing Flow Fields of Non-equidistant Group Holes to Enhance Efficiency and Surface quality in Online Deformation Electrochemical Cutting

Online deformation electrochemical cutting with flexible electrode (FECC) is a novel process utilising simple electrodes to machine complex surfaces, offering broad application prospects in the manufacture of aero-engine components. However, the continuous deformation of the flexible electrode during this process results in a complex flow field within the machining gap and an uneven velocity distribution, readily creating low-velocity zones that compromise machining stability and surface finish quality. To address this, this paper proposes a novel flow field model based on non-equidistant group holes electrodes. Firstly, through mechanical simulation and deformation experiments, it was verified that non-equidistant group holes electrodes exhibit higher stiffness and structural stability compared to traditional equidistant group holes electrodes. Subsequently, flow field simulations and machining experiments were conducted, comparing the novel flow field with the conventional flow field. Simulation results demonstrated that the new flow field significantly enhanced both the flow velocity and uniformity of the electrolyte within the machining gap. Experiment results demonstrated that the new flow field achieved a maximum stable machining speed of 0.8 mm/min, representing a 60% improvement over the conventional flow field. Concurrently, the surface roughness of the machined surfaces decreased to Ra 1.754 µm, representing an approximately 50% improvement in surface quality. To further enhance surface quality, auxiliary flushing measures were introduced, effectively reducing stray corrosion phenomena on the workpiece end faces. Ultimately, by combining the non-equidistant group holes flow field with auxiliary flushing technology, high-quality deformation channels with minimal surface corrosion and excellent surface finish were successfully fabricated. The non-equidistant group holes flow field and auxiliary flushing method proposed in this study significantly enhance the machining efficiency and surface finish quality of FECC, providing valuable technical reference for the precision machining of complex aerospace engine components.