Electrochemical machining of the spiral internal turbulator

Electrochemical machining (ECM) is promising to machine the complex surface due to the advantages of no tool wear, stress free, and good machining accuracy. In this study, a machining method of the spiral internal ribs by ECM is presented. Firstly, the ECM experimental system is developed, which consists of electrolyte supply module, power supply unit, and workpiece-holding device. Then, a shaped cathode was used to process the spiral-turbulated hole on the built system. The shaped cathode was prepared by means of ultraviolet-curing mask method considering the expected spiral turbulator’s shape. Furthermore, parameters affecting the machining accuracy in shape duplication and machining efficiency are analyzed and discussed, especially the voltage and electrolyte concentration which have the main effect on the processed results.

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