Optimizing electrochemical turning of titanium matrix composites: Enhancing efficiency with inclined cathode tools

Titanium matrix composites (TMC) are difficult to machine due to their excellent performance. This study proposes improving their machining efficiency through electrochemical turning (ECT) technology. Unlike traditional profiling cathodes, a rectangular cathode tool with side outlet was used to optimize the electrolyte flow velocity in the machining area by adjusting the tool tilt angle. The objective of this study is to investigate the potential of ECT technology for the machining of TMC, utilizing a general rectangular cathode to address the prolonged preparation cycles and limited flexibility of traditional copy-style cathodes. The experiments found that when the cathode was tilted at 60°, the single-circle removal thickness (SRT) increased by 167.1 % compared to traditional center outlet tools, and the surface roughness was reduced by 63.5 %. By controlling parameters such as voltage, rotation speed, and workpiece orientation, the machining efficiency and surface quality of TMC were significantly improved, providing a new solution for efficient and precise machining of difficult-to-machine materials in the aerospace field.