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<p>Counter-rotating electrochemical machining (CRECM) is an effective method for the large-scale removal of difficult-to-machine materials from revolving parts, offering high machining efficiency, no residual stress, and zero tool wear. However, as the height of the CRECM-processed convex structure increases, stray corrosion caused by submerged machining becomes increasingly severe, reducing the accuracy of high-convex features (height &gt; 10 mm). To address this limitation, this study proposes a novel electrolyte flow strategy: CRECM with internal flushing (IF-CRECM). In this approach, the electrolyte flows from the electrode through outlet slits into the inter-electrode gap (IEG), and the degree of electrolyte diffusion is controlled by varying the number of slits, thereby suppressing stray corrosion. A multiphysics model coupling gas-liquid two-phase flow with electric field distribution is developed to investigate the corrosion suppression mechanism of IF-CRECM. Detailed analyses of the gas-liquid distribution and stray current behavior in submerged CRECM and IF-CRECM confirm that the electrolyte is effectively confined within the IEG, resulting in a substantial reduction in the stray corrosion of convex structures during counter-rotation. Experimental validation further demonstrates that IF-CRECM achieves a 93.96% reduction in the stray corrosion area compared with submerged CRECM. The processed high-convex structure exhibits an inverted conical cross-section consistent with the cathode tool trajectory, reaching a height of 10.93 mm with a minimum top stray corrosion depth of just 0.07 mm.</p>

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Fabrication of high-convex structures on revolving parts via counter-rotating electrochemical machining with internal flushing

  • 期刊论文

  • 发表日期：

    2025年10月23日

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  • Huayong Le,
  • Dengyong Wang,
  • Jun Zhang,
  • Tianyu Fu,
  • Di Zhu

摘要

Counter-rotating electrochemical machining (CRECM) is an effective method for the large-scale removal of difficult-to-machine materials from revolving parts, offering high machining efficiency, no residual stress, and zero tool wear. However, as the height of the CRECM-processed convex structure increases, stray corrosion caused by submerged machining becomes increasingly severe, reducing the accuracy of high-convex features (height > 10 mm). To address this limitation, this study proposes a novel electrolyte flow strategy: CRECM with internal flushing (IF-CRECM). In this approach, the electrolyte flows from the electrode through outlet slits into the inter-electrode gap (IEG), and the degree of electrolyte diffusion is controlled by varying the number of slits, thereby suppressing stray corrosion. A multiphysics model coupling gas-liquid two-phase flow with electric field distribution is developed to investigate the corrosion suppression mechanism of IF-CRECM. Detailed analyses of the gas-liquid distribution and stray current behavior in submerged CRECM and IF-CRECM confirm that the electrolyte is effectively confined within the IEG, resulting in a substantial reduction in the stray corrosion of convex structures during counter-rotation. Experimental validation further demonstrates that IF-CRECM achieves a 93.96% reduction in the stray corrosion area compared with submerged CRECM. The processed high-convex structure exhibits an inverted conical cross-section consistent with the cathode tool trajectory, reaching a height of 10.93 mm with a minimum top stray corrosion depth of just 0.07 mm.