Influence of different parameters on processing efficiency in electrochemical machining

In order to investigate the effects of different cathode diameters and electrolyte concentrations on the efficiency and surface morphology of electrochemical finishing, we used finite element analysis software for simulation to explore the trend of changes in removal amount under different cathode diameters and electrolyte concentrations. Meanwhile, the effects of different electrolyte concentrations and cathode diameters on machining efficiency were compared through experiments. The research results indicate that as the cathode diameter and electrolyte concentration increase, the removal amount also increases. After electrochemical finishing, the values of surface micro high and micro low points were reduced from 40.64 μm to 27.33 μm. The original "peak" shape in the microstructure was flattened into a "circular arc" shape, significantly improving the precision machining effect. This research result indicates that by appropriately adjusting parameters such as cathode diameter and electrolyte concentration, the removal amount and surface quality of electrochemical finishing can be effectively controlled, providing an excellent solution for precision machining of metal parts.