Segmented electrochemical milling of large and difficult-to-machine curved surfaces

In aerospace and other industrial manufacturing domains, the use of parts with large and difficult-to-machine thin-walled curved surfaces is widespread. Achieving good surface morphology when processing these curved structural parts is a critical research focus due to their insufficient stiffness, variability and susceptibility to noticeable tool marks. This study conducted experimental research based on the principle of electrochemical milling (EC milling) of surfaces, considering different machining sequences. The processing sequence of "first middle and then two sides" obtained a superior surface morphology. Secondly, to address the issue of tool marks, tools with different outlet surface lengths were designed. The results demonstrate that increasing the outlet surface length to 20 mm minimized machining depth deviation, roundness error, and tool marks on the machined surface. Ultimately, the experiment confirmed the feasibility of enhancing tool marks by adjusting the length of the outlet surface, thereby achieving excellent surface morphology in the processed workpieces.