Massive Meso Holes On TC4Sheet By Pulse Electrochemical Machining With Moveable Cathode Mask

Electrochemical machining (ECM) is a kind of machining based on electrochemical principleand molding cathode, utilizing electrolytic cell to dissolve workpiece and then process the workpieceinto desired shape and size. With the development of the aerospace industry, ECM plays anincreasingly important role in the industry. Moveable cathode mask electrochemical machining, asone way of ECM, is distinctly superior in machining sheet with multiholes. As industrial technologymatures, the application of moveable cathode mask electrochemical machining to workpiece with alarge area of multiple micro holes presents an enormous challenge.This paper explores the application of moveable cathode mask impulse ECM to TC4sheet withmultiple micro holes with the help of established theories and moveable cathode mask ECM process.Through a series of test analysis, the current paper investigates the effects of template parameters,electrolyte parameters and electrical parameters on machining results, and then optimizes theseparameters based on the experimental analysis. The optimized parameters are applied in experimentsof moveable cathode mask impulse ECM on large sized TC4sheet.1. The processing method for cathode mask is developed, including the use of PVC special drillbits, drill feed rate and lower padded sacrifice panels;2. Special fixture of ECM for multiple micro holes is improved. Specific improvements include:cylinder shaped rubber being employed in both the upper and lower clamps to support fixture andmask; the side insulation of fixture; and applying different positioning pins towards fixture and mask.3. Experiments have been conducted on mask parameters, electrolyte test parameters andelectrical parameters with the help of special fixture of ECM. Through research and analysis, theoptimum parameters for machining TC4sheet are obtained.4. The optimum parameters obtained by experimental analysis are applied to a large area of TC4sheet for ECM, and workpiece with good surface and high integrity is produced.The experimental results show that TC4sheet of high precision massive array meso holes couldbe obtained using aperture of mask with2.5mm, thickness of mask with0.1mm/0.3mm(conductorthickness/total thickness), temperature of the electrolyte with45℃, pulse duty cycle with20%, pulsefrequency with400Hz.