Enhancing computer numerical control machining quality through electrochemical anodic dissolution

Abstract

Current research on interpolation technology has not considered the material removal mechanism. Therefore, this study investigates the application of electrochemical anodic dissolution in the finishing process of computer numerical control (CNC) machining to mitigate the impact of short line segment tool paths on part machining quality. Based on the principles of CNC machining, tool geometry, and material removal characteristics during the electrochemical anodic dissolution process, this study first employs the finite element method (FEM) to analyze the effects of six different cylindrical cathode working surfaces (d = 2.5, 3, 3.5, 4, 4.5, 5 mm) on the potential and current density in the electrochemical anodic dissolution process, with results validated through a single-factor experiment. The findings indicate that differences in the cathode working surface directly affect the potential, current density, and their distribution on the workpiece surface, thereby influencing the quality and efficiency of electrochemical polishing (EP). Additionally, when the process parameters are the same, a cathode with a diameter of 2.5 mm has a more significant effect on the unit processing area and material removal rate compared to other cathode sizes. Furthermore, insulating the cathode sidewalls enhances localized machining but results in lower processing efficiency, with a surface roughness value higher than that obtained with a conventional cathode. More importantly, EP involves various controllable electrical parameters and peak current effects that can transform spike structures into arcs or rounded corners, thereby forming a smooth, wavy surface. This study combines electrochemical anodic dissolution with CNC machining, providing new insights and methods for enhancing precision interpolation technology and CNC machining quality.