Experiment and Modelling of Triangular Holes Array by Non-traditional Machining Process

Abstract

Triangular holes array is a common structure of the specially shaped holes that can be used for various products in aerospace vehicles. These are commonly produced in the electrochemical machining (ECM) process. The high-quality and accuracy of a triangular grid are closely related to the processing parameters of cathode structure and sidewall insulation sleeve, power supply, electrolyte flow rate, feed speed, and machining gap. Simulations have been carried out to consider the influence of parameters including structure and dimension of the cathode, initial machining gap, feed speed, and current on the homogeneity of the flow field in the machining gap. Consequently, the modeling can support the design of the cathode. The paper is divided into two parts. Firstly, the tool cathode is simulated and fabricated. Secondly, the triangular holes array is produced by using the designed cathode tool. It was found that higher feed speed and lower machining gap increase the stability, accuracy, and efficiency of the machining process and the quality of the triangular holes array.