A comparative study on the effects of magnetic field on the anode surface roughness in the forward and reverse electrolyte feed pattern during electrochemical machining

  • Li Long
  • Baoji MaEmail author
  • Peiyong Cheng
  • Kang Yun
  • Honghong Gao


This study investigates effects of electrolyte feed patterns on the anode surface roughness in magnetic field–assisted ECM. Physical and mathematical models of forward feed and reverse feed of electrolyte are constructed using commercial COMSOL Multiphysics software, and the current density at the anode surface is simulated. In order to verify the correctness of the model and simulation results, we carried out an experimental study. According to the simulation results, the anode surface current density obtained by the electrolyte reverse feed is higher than that by forward feed. Moreover, the magnetic field is found to increase the anode surface current density in both forward and backward feeds of electrolyte. Meanwhile, experimental results show that the Ra by electrolyte reverse feed is smaller than that by forward feed, and in both feeds, the presence of magnetic field can contribute to the reduction of Ra value. It can be concluded that the magnetic field plays a positive role in improving the anode surface roughness during ECM, and the introduction of magnetic field into forward feed ECM results in a higher surface roughness than that into reverse feed ECM. Such conclusions are of great significance to widen the application of the extended magnetic field–assisted ECM.


Electrochemical machining Flow field Magnetic field Forward flow Reverse flow Surface roughness 


Unable to display preview. Download preview PDF.

Unable to display preview. Download preview PDF.



The authors also would like to thank Dr. Peili Yin of Xi’an Technological University for her helpful suggestion.

Funding information

This study was supported by Open Research Fund Program of Shaanxi Key Laboratory of Non-Traditional Machining (Grant No. 2017SXTZKFJG02) and project funded scientific research project of Key Laboratory of Shaanxi Provincial Department of Education (Grant No. 17JS056).


  1. 1.
    Xu Z, Sun L, Hu Y, Zhang J (2014) Flow field design and experimental investigation of electrochemical machining on blisk cascade passage. Int J Adv Manuf Technol 71(1–4):459–469CrossRefGoogle Scholar
  2. 2.
    Zhu D, Zhang J, Zhang K, Liu J, Chen Z, Qu N (2015) Electrochemical machining on blisk cascade passage with dynamic additional electrolyte flow. Int J Adv Manuf Technol 80(1–4):637–645CrossRefGoogle Scholar
  3. 3.
    Zhu D, Zhang R, Liu C (2017) Flow field improvement by optimizing turning profile at electrolyte inlet in electrochemical machining. Int J Precis Eng Manuf 18(1):15–22CrossRefGoogle Scholar
  4. 4.
    Gu Z, Zhu D, Xue T, Liu A, Zhu D (2016) Investigation on flow field in electrochemical trepanning of aero engine diffuser. Int J Adv Manuf Technol 1–8Google Scholar
  5. 5.
    Klocke F, Zeis M, Klink A (2015) Interdisciplinary modelling of the electrochemical machining process for engine blades. CIRP Ann Manuf Technol 64(1):217–220CrossRefGoogle Scholar
  6. 6.
    Sekar T, Arularasu M, Sathiyamoorthy V (2016) Investigations on the effects of nano-fluid in ECM of die steel. Measurement 83(3):38–43Google Scholar
  7. 7.
    Pa PS (2009) Super finishing with ultrasonic and magnetic assistance in electrochemical micro-machining. Electrochim Acta 54(25):6022–6027CrossRefGoogle Scholar
  8. 8.
    Jia JL, Fan ZJ (2011) Research on higher frequency, short pulses and assisted magnetic field electrochemical machining. Adv Mater Res 189-193:3162–3165CrossRefGoogle Scholar
  9. 9.
    Tang L, Yang F, Zhu QL, Gan WM (2016) Electrochemical machining flow field simulation and experimental verification for irregular vortex paths of a closed integer impeller. Int J Adv Manuf Technol 83(1–4):275–283CrossRefGoogle Scholar
  10. 10.
    Kang BY, Fan ZJ, Tang L (2015) Design and analysis of flow field in electrochemical machining of cochlear channel of closed integral structure. Acta ArmamentariiGoogle Scholar
  11. 11.
    Hewidy MS, Ebeid SJ, El-Taweel TA et al (2007) Modelling the performance of ECM assisted by low frequency vibrations. J Mater Process Technol 189(1):466–472CrossRefGoogle Scholar
  12. 12.
    Fan Z, Zhang L, Tang L (2008) Influence of magnetic field on accuracy of ECM by changing the conductivity of anode film. Chin J Mech Eng 21(4):11–14CrossRefGoogle Scholar
  13. 13.
    Takeda M, Okuji Y, Akazawa T, Liu X, Kiyoshi T (2005) Fundamental studies of helical-type seawater MHD generation system. IEEE Trans Appl Supercond 15(2):2170–2173CrossRefGoogle Scholar
  14. 14.
    Mayo RM, Mills RL, Nansteel M (2002) On the potential for direct or MHD conversion of power from a novel plasma source to electricity for microdistributed power applications. IEEE Trans Plasma Sci 30(4):1568–1578CrossRefGoogle Scholar
  15. 15.
    Tang L, Gan WM (2014) Experiment and simulation study on concentrated magnetic field-assisted ECM S-03 special stainless steel complex cavity. Int J Adv Manuf Technol 72(5–8):685–692CrossRefGoogle Scholar
  16. 16.
    Li L, Baoji MA (2018) Effect of magnetic field on anodic dissolution in electrochemical machining. Int J Adv Manuf Technol 94(1–4):1177–1187Google Scholar
  17. 17.
    Zhu D, Zhu D, Xu Z, Xu Q, Liu J (2010) Investigation on the flow field of w-shape electrolyte flow mode in electrochemical machining. J Appl Electrochem 40(3):525–532CrossRefGoogle Scholar
  18. 18.
    Zhu D, Gu Z, Xue T, Zhu D (2016) Flow field design in electrochemical machining of diffuser. Procedia Cirp 42:121–124CrossRefGoogle Scholar

Copyright information

© Springer-Verlag London Ltd., part of Springer Nature 2018

Authors and Affiliations

  • Li Long
    • 1
    • 2
  • Baoji Ma
    • 1
    • 2
    Email author
  • Peiyong Cheng
    • 1
  • Kang Yun
    • 1
  • Honghong Gao
    • 1
  1. 1.School of Mechanical EngineeringXi’an Technological UniversityXi’anChina
  2. 2.Shaanxi Key Laboratory of Non-Traditional MachiningXi’an Technological UniversityXi’anChina

Personalised recommendations