Investigation of the influence of electrolytic milling machining parameters on the machining accuracy of thin-walled parts

Aircraft parts are often designed as thin-walled structures to reduce the weight of the aircraft. However, thin-walled structures are prone to deformation during the milling process, leading to a decrease in machining accuracy. To address this problem, a method combining milling and electrochemical machining, known as electrolytic milling, is proposed to minimize deformation and enhance the accuracy of thin-walled parts. The factors that affect the machining accuracy of electrolytic milling were analysed, and a model for predicting the thickness of the material removed was established. Electrolytic milling experiments were designed, and the model was solved. Based on the built model, the influences of feed rate, spindle speed, radial cutting depth, voltage and electrolyte concentration on material removal thickness were investigated. Compared with the milling method, the electrolytic milling method can improve the machining accuracy of thin-walled parts. Electrolytic milling experiments were conducted on box-shaped parts to verify the reliability of the proposed method.