Localized sinking electrochemical machining of pre-shaped convex structure on revolution surface using specifically designed cathode tool

Counter-rotating electrochemical machining (CRECM) is an effective method for machining thin-walled revolving parts with complex structures. However, it is difficult to achieve a desirable uniform straight sidewall during the CRECM of isolated convex structures with variable cross-sectional profiles, so a subsequent local machining process is necessary. In this paper, a localized sinking ECM method is proposed to locally machine a pre-shaped convex structure by CRECM. A mathematical model is established to analyze the anode shaping process. In addition, a special cathode tool is designed to control the junction mark between the subsequent dissolution regions and the surrounded non-machined areas. The simulation and experimental results indicate that the sidewall profiles of the convex structure can be improved remarkably. In lateral view, convex side wall taper is reduced from 21.81 degrees to 3.05 degrees, In front view, convex side wall taper is reduced from 6.45 degrees to 0.28 degrees, Furthermore, the junction mark can be effectively controlled to within 0.07 mm.