Research on mechanism and experimental effect of tubular electrode dimensions on electric arc electrochemical composite machining

This research discusses the effect of typical characteristic dimensions of electrodes on electric arc electrochemical composite machining (EAECM). The flow rate and debris removal capability of electrodes with different characteristic dimensions were investigated by flow field simulation. Single-factor machining experiments were conducted. The discharge characteristics, process indicators and machined surfaces of electrodes were analyzed it was found that the tubular electrode has a demarcation phenomenon that affects the surface quality. The results indicate that the use of electrodes with large inner diameters is favorable to improve the surface consistency. The use of electrodes with small outer diameters improves the overall surface quality but increases the electrode wear. Finally, the fracture mechanism of thin-walled electrodes was revealed by stress field simulations and experiments. In conclusion, in order to improve the machining effect of EAECM, large-diameter (inner and outer diameter) electrodes with wall thickness greater than 2 mm should be selected.