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<p>Micro thin-walled components, characterized by wall thicknesses often below 100 μm, are critical in precision engineering, yet their fabrication poses significant challenges to conventional manufacturing technologies. To address this, a novel Flying Wire Electrochemical Turning (FWECT) process is proposed in this paper for the micro-machining of such components. A predictive model was established by integrating Response Surface Methodology (RSM) with the Box-Cox transformation, creating a statistically robust framework capable of handling non-normal data. Guided by this model, we systematically investigated the effects of key process parameters (rotation speed, pulse width, voltage, and feed rate) on material removal rate, machining overcut, surface roughness, and transition fillet radius. Finally, the optimal machining parameters: an applied voltage of 16.28 V, pulse width of 477 ns, rotation speed of 1000 r/min, and feed rate of 0.85 μm/s, were employed for fabrication. Using these parameters, ultra-long tubular components with a wall thickness of 55 μm and smooth transition fillets were successfully fabricated. These results validate the high accuracy of the predictive model and demonstrate the capability of the FWECT process for manufacturing high-precision micro thin-walled components.</p>

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Optimization of flying wire electrochemical turning for high-precision micro thin-walled component machining

  • 期刊论文

  • 发表日期：

    2026年1月21日

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  • Ying Li,
  • Yanliang Li,
  • Rudong Zhang,
  • Yongbin Zeng

摘要

Micro thin-walled components, characterized by wall thicknesses often below 100 μm, are critical in precision engineering, yet their fabrication poses significant challenges to conventional manufacturing technologies. To address this, a novel Flying Wire Electrochemical Turning (FWECT) process is proposed in this paper for the micro-machining of such components. A predictive model was established by integrating Response Surface Methodology (RSM) with the Box-Cox transformation, creating a statistically robust framework capable of handling non-normal data. Guided by this model, we systematically investigated the effects of key process parameters (rotation speed, pulse width, voltage, and feed rate) on material removal rate, machining overcut, surface roughness, and transition fillet radius. Finally, the optimal machining parameters: an applied voltage of 16.28 V, pulse width of 477 ns, rotation speed of 1000 r/min, and feed rate of 0.85 μm/s, were employed for fabrication. Using these parameters, ultra-long tubular components with a wall thickness of 55 μm and smooth transition fillets were successfully fabricated. These results validate the high accuracy of the predictive model and demonstrate the capability of the FWECT process for manufacturing high-precision micro thin-walled components.