<p>Controllable electrolyte distribution electrochemical machining (CED-ECM) is an unconventional electrochemical machining (ECM) technique designed to mitigate the adverse effects of stray corrosion. Unlike conventional ECM methods, this method positions the tool electrode beneath the workpiece and employs a porous solid ball as an electrolyte reservoir to confine electrolyte distribution, enabling targeted electrolyte delivery to the machining zone via capillary action. However, its applicability is limited for large-scale workpieces that are difficult to reposition. To address this, a novel writing-style CED-ECM method is proposed, inspired by the CED-ECM principle. This method utilizes a ballpoint pen-like tool with a nib-like structure, enabling precise, handwriting-analogous operation that significantly expands the applicability of CED-ECM theory. Experiments were systematically conducted to investigate the impacts of tool travel speed and machining current on the processing results. The results demonstrate that the writing-style CED-ECM method effectively suppresses stray corrosion at the boundary of the processed area and the unprocessed area while inducing a depth variation across the machined groove: the processed groove’s edge regions exhibit greater depth (approximately 16 µm) compared to the processed groove’s central area (about 8–14 µm) due to the electrolyte distribution. Under district current and machining time, a groove with a maximum depth of 16 µm and a width of 9 mm was achieved at the ballpoint pen-like tool moving speed of 10 mm/s. This study provides valuable experimental insights and theoretical foundations for the practical implementation and further optimization of writing-style CED-ECM in industrial applications, such as replacing hand scraping operations.</p>

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Writing-style controllable electrolyte distribution electrochemical machining (CED-ECM) method with porous solid ball as electrolyte confinement material based on CED-ECM theory

  • Jiankang Wang,
  • Wei Wang,
  • Yexuan Zhang,
  • Kailiang Geng,
  • Masaki Daiku,
  • Wataru Natsu

摘要

Controllable electrolyte distribution electrochemical machining (CED-ECM) is an unconventional electrochemical machining (ECM) technique designed to mitigate the adverse effects of stray corrosion. Unlike conventional ECM methods, this method positions the tool electrode beneath the workpiece and employs a porous solid ball as an electrolyte reservoir to confine electrolyte distribution, enabling targeted electrolyte delivery to the machining zone via capillary action. However, its applicability is limited for large-scale workpieces that are difficult to reposition. To address this, a novel writing-style CED-ECM method is proposed, inspired by the CED-ECM principle. This method utilizes a ballpoint pen-like tool with a nib-like structure, enabling precise, handwriting-analogous operation that significantly expands the applicability of CED-ECM theory. Experiments were systematically conducted to investigate the impacts of tool travel speed and machining current on the processing results. The results demonstrate that the writing-style CED-ECM method effectively suppresses stray corrosion at the boundary of the processed area and the unprocessed area while inducing a depth variation across the machined groove: the processed groove’s edge regions exhibit greater depth (approximately 16 µm) compared to the processed groove’s central area (about 8–14 µm) due to the electrolyte distribution. Under district current and machining time, a groove with a maximum depth of 16 µm and a width of 9 mm was achieved at the ballpoint pen-like tool moving speed of 10 mm/s. This study provides valuable experimental insights and theoretical foundations for the practical implementation and further optimization of writing-style CED-ECM in industrial applications, such as replacing hand scraping operations.