Evolution of convex structure during counter-rotating electrochemical machining based on kinematic modeling

Counter-rotating electrochemical machining (CRECM) is a novel electrochemical machining (ECM) method, which can be used to machine convex structures with complex shapes on the outer surface of casings. In this study, the evolution of the convex structure during CRECM is studied. The complex motion form of CRECM is replaced by an equivalent kinematic model, in which the movement of the cathode tool is realized by matrix equations. The trajectory of the cathode tool center satisfies the Archimedes spiral equation, and the feed depth in adjacent cycles is a constant. The simulation results show that the variations of five quality indexes for the convex structure: as machining time increases, the height increases linearly, and the width reduces linearly, the fillets at the top and root fit the rational function, and the inclination angle of the convex satisfies the exponential function. The current density distributions with different rotation angles is investigated. Owing to the differential distribution of current density on workpiece surface, the convex is manufactured with the cathode window transferring into and out of the processing area. Experimental results agree very well with the simulation, which indicates that the proposed model is effective for prediction the evolution of the convex structure in CRECM.