Experimental study on ECM with a grid cathode composed of circular cells

In order to resolve the problem of single machining object existing in traditional electrochemical machining (ECM) with unitary cathode, a grid cathode composed of circular cells is used to produce the workpieces with different shapes. Three types of circular cells, ??1.5 mm, ??2.0 mm, and ??2.5 mm, are utilized to construct the plane, slant, and blade cathode. The material of the cathode and the anode is CrNi₁₈Ti₉, and the ingredient of electrolyte is 15% NaCl and 15% NaNO₃. The machining balance current and the balance time are acquired and analyzed, the machining process and the workpiece quality are compared between using the grid cathode and the unitary cathode. Moreover, the machining errors and the error reasons of workpiece surface are analyzed. Research shows that the grid cathode can be used to manufacture workpieces with a complex shape, and the workpiece quality is better if the circular cell is smaller. If the circular cell is small enough the workpiece quality is almost equal to it machined by the unitary cathode.