Abstract: Precision electrochemical machining is one of the main machining methods to process the arrayed arc-shaped multi-grooves in the shavering cap. In order to improve the machining accuracy and machining stability, critical height and width dimensions of bulge which in the cathode are optimized based on the electric field analysis, besides, design of electrolyte flow channel and the parameters selection of inlet pressure and outlet pressure are optimized which based on the flow field numerical analysis, and the regions in the flow channel which lack of electrolyte and cross-streamline are eliminated, as a result, the dedicated clamping fixture is developed. The influence of groove width are studied by experiments with end initial gap, average voltage, feed rate and other critical machining parameters. Meso scale arc-shaped multi-grooves which groove width 0.24 mm can be obtained by adopting dedicated numerical electrochemical machining equipment, besides; the multi-grooves are with highly arc shape precision and improved machining stability so as to meet the needs of production.

Key words: arc-shaped multi-grooves, electric field analysis, electrochemical machining, flow field design, meso scale