Flow field optimization for electrochemical machining of pit arrays in multiple rows

The flow field distribution is important to the processing quality of array structures in electrochemical machining (ECM). To solve the problem of poor consistency of multiple rows of pits, a flow field optimization method was proposed to reduce the height of the cathode teeth and add the flow channel and transition region. The flow field simulation results showed that there was evaporation under the initial flow field, and the flow velocity in the processing area of multiple rows of pits gradually decreased. The flow of electrolyte in the optimized flow field was more concentrated, the flow velocity in the processing area was greater than that in the non-processing area between rows, and the flow velocity in multiple rows of pits was more uniform. The pit arrays of 6 rows × 10 columns were processed by using the initial and optimized flow field. The pit arrays processed with the optimized flow field are more consistent; the standard deviations (SD) of the depth, length, and width of pits are 3.87μm, 10.16μm and 12.02μm, respectively. In addition, the optimized flow field also helps to reduce stray corrosion. This research has certain reference value for solving the processing problem of the anvil part of the endoscopic stapler.