Research on counter-rotating electrochemical machining of convex structures with different heights

  • Bin He
  • Dengyong WangEmail author
  • Zengwei Zhu
  • Jinzheng Li
  • Di Zhu


Counter-rotating electrochemical machining (CRECM) is an alternative method for the manufacture of aero-engine casing parts with complex convex structures. In previous studies, the revolving part with hollow windows was used as the cathode tool. However, only convex structures with the same height could be machined. In practice, there are usually differences in height between different convex structures on the surface of most casing parts. To machine convex structures of different heights by using CRECM, a specific cathode with concave cavities has been designed. The bottom surfaces of concave cavities are conductive, and the depths of concave cavities are changed according to the height of convex structures. The material of the workpiece in this study is Inconel 718. Forming processes of convex structures with the cathode are simulated by using the finite element method. Results show that during the processing, the top surface of the convex structure is gradually changed from stray corrosion at low current density to normal dissolution at high current density. The height of the convex structure increases and then approximately keeps constant with increasing amount of feed, and it also can be controlled by changing the depth of the concave cavity. Finally, convex structures of different heights on the cylindrical workpiece are machined experimentally, verifying the feasibility of the method.


Counter-rotating Electrochemical machining Convex structures Concave cavity 


Funding information

This study was financially supported by the State Key Program of National Natural Science Foundation of China (51535006, 51805259), and Fundamental Research Funds for the Central Universities (3082018NP2018406), and Foundation Research Project of Jiangsu Province (BK20180431), and Young Elite Scientists Sponsorship Program by CAST, and Jiangsu Key Laboratory of Precision and Micro-Manufacturing 2 Technology.


  1. 1.
    Klocke F, Zeis M, Klink A, Veselovac D (2013) Experimental research on the electrochemical machining of modern titanium-and nickel-based alloys for aero engine components. Proc CIRP 6:368–372CrossRefGoogle Scholar
  2. 2.
    Rajurkar KP, Zhu D, Mcgeough JA, Kozak J, DeSilva A (1999) New developments in electrochemical machining. Ann CIRP 48:567–579CrossRefGoogle Scholar
  3. 3.
    Gu ZZ, Zhu WG, Zheng XH, Bai XM (2019) Cathode tool design and experimental study on electrochemical trepanning of blades. Int J Adv Manuf Technol 100:857–863CrossRefGoogle Scholar
  4. 4.
    Klocke F, Schmitt R, Zeis M, Heidemanns L, Kerkhoff J, Heinen D, Klink A (2015) Technological and economical assessment of alternative process chains for blisk manufacture. Proc CIRP 35:67–72CrossRefGoogle Scholar
  5. 5.
    Williams James C, Starke EA (2003) Progress in structural materials for aerospace systems. J Acta Materialia 51(19):5775–5799CrossRefGoogle Scholar
  6. 6.
    Kolluru K, Axinte D (2013) Coupled interaction of dynamic responses of tool and workpiece in thin wall milling. J Mater Process Technol 213(9):1565–1574CrossRefGoogle Scholar
  7. 7.
    Gao YY, Ma JW, Jia ZY, Wang FJ, Si LK, Song DN (2016) Tool path planning and machining deformation compensation in high-speed milling for difficult-to-machine material thin-walled parts with curved surface. Int J Adv Manuf Technol 84:1757–1767CrossRefGoogle Scholar
  8. 8.
    Sheng W, Xu B (2010) Technological test of electrolytic machining of aero-engine casing. Electromach Mould 2:52–59Google Scholar
  9. 9.
    Wang DY, Zhu ZW, Wang HR, Zhu D (2016) Convex shaping process simulation during counter-rotating electrochemical machining by using the finite element method. Chin. J Aeronaut 29:534–541CrossRefGoogle Scholar
  10. 10.
    Hocheng H, Sun YH, Lin SC, Kao PS (2003) A material removal analysis of electrochemical machining using flat-end cathode. J Mater Process Technol 140(1-3):264–268CrossRefGoogle Scholar
  11. 11.
    Pattavanitch J, Hinduja S, Atkinson J (2010) Modelling of the electrochemical machining process by the boundary element method. Ann CIRP 59(1):243–246CrossRefGoogle Scholar
  12. 12.
    Purcar M, Bortels L, Bossche BVD, Deconinck J (2004) 3d electrochemical machining computer simulations. J Mater Process Technol 149(1):472–478CrossRefGoogle Scholar
  13. 13.
    Wang DY, Zhu ZW, Wang NF, Zhu D, Wang HR (2015) Investigation of the electrochemical dissolution behavior of Inconel 718 and 304 stainless steel at low current density in NaNO3 solution. Electrochim Acta 156:301–307CrossRefGoogle Scholar
  14. 14.
    Gok A (2015) A new approach to minimization of the surface roughness and cutting force via fuzzy TOPSIS, multi-objective grey design and RSA. Measurement 70:100–109CrossRefGoogle Scholar

Copyright information

© Springer-Verlag London Ltd., part of Springer Nature 2019

Authors and Affiliations

  • Bin He
    • 1
  • Dengyong Wang
    • 1
    Email author
  • Zengwei Zhu
    • 1
  • Jinzheng Li
    • 1
  • Di Zhu
    • 1
  1. 1.Nanjing University of Aeronautics and AstronauticsNanjingPeople’s Republic of China

Personalised recommendations