Prediction and Verification of Feed Rate in Electrochemical Finishing of Additively Manufactured Interior Channels

doi:10.3901/JME.260705

Abstract

Abstract: Electrochemical finishing is an effective method to improve the surface quality of additively manufactured interior channels. The feed rate is related to many factors such as processing voltage, inter-pole gap, and initial roughness. However, current research rarely takes these factors into comprehensive consideration. The effect of cathode axial feed speed on surface quality and machining efficiency is significant. In order to determine a reasonable feed rate, the mathematical model of feed rate prediction is established and solved numerically based on the surface microscopic profile characteristics of additive manufacturing parts and electrochemical material dissolution law. The analysis shows that the reasonable range of machining voltage and gap is 10～25 V and 0.2～0.5 mm, respectively. Overlarge voltage and too small gap have no significant effect on improving the feed rate, and on the contrary, they are detrimental to the finishing efficiency. The predicted feed rate and process parameters are verified by experiments. The results show that when the machining voltage is 10 V and the machining gap is 0.5 mm, the surface quality of the specimen is significantly improved by selecting the predicted feed rate of 0.85 mm/min. The surface roughness Ra and Rz decreased from 10.25 μm and 49.42 μm to 2.26 μm and 12.59 μm, respectively. The prediction error of Rz is only 4.89%, and the aperture accuracy meets the machining requirements, the results provide a theoretical basis for the selection of internal flow channel electrolytic processing parameters.

Key words: electrochemical finishing, additive manufacturing, interior channel, feed rate, prediction

CLC Number:

TG156

AN Linchao, WANG Dengyong, ZHU Di. Prediction and Verification of Feed Rate in Electrochemical Finishing of Additively Manufactured Interior Channels[J]. Journal of Mechanical Engineering, 2026, 62(13): 434-443.

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URL: http://www.cjmenet.com.cn/EN/10.3901/JME.260705

http://www.cjmenet.com.cn/EN/Y2026/V62/I13/434

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