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Review | Open Access

Macro electrochemical milling and its hybrid variants

Ningsong QUa,( ), Xiaolong FANGa, Junzhong ZHANGa, Huanghai KONGa, Yang LIUb, Minglu WANGc, Xiaokang YUEd, Yuehong MAa, Zhihao SHENa, Jiajie CHENa
College of Mechanical and Electrical Engineering, Nanjing University of Aeronautics and Astronautics, Nanjing 210016, China
School of Mechanical Engineering, Jiangsu University, Zhenjiang 212003, China
School of Mechanical Engineering, Jiangsu University of Science and Technology, Zhenjiang 212003, China
School of Mechanical Engineering, Hefei University of Technology, Hefei 230009, China

Peer review under responsibility of Editorial Committee of CJA.

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Abstract

Macro electromechanical milling has recently attracted increasing attention because numerous large thin-walled structures composed of difficult-to-cut materials are employed in the aerospace field. This paper reviews recent developments in state-of-the-art macro electromechanical milling. The fundamental aspects of material removal mechanisms, such as the generation and breakdown behaviors of passive oxide films of typical difficult-to-cut materials, were discussed. Rapid methods for breaking down passive films are summarized, and simulation methods for the machining process coupling multiple physical fields are introduced. Specific electrochemical milling methods, including fly mode electrochemical milling and sink electrochemical milling, are classified. Efforts made to improve process performance, such as the material removal rate, surface quality, and machining accuracy, are discussed. In addition, the main hybrid electrochemical milling methods, including electrochemical discharge milling, mechano-electrochemical milling, and electrochemical mill grinding, are also presented.

Keywords

Material removal rateSurface qualityElectrochemical machiningElectrochemical millingElectrochemical discharge millingElectrochemical mill-grinding

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Chinese Journal of Aeronautics
Volume 37 Issue 8,
August 2024
Pages 1-35
DOI: 10.1016/j.cja.2023.12.015
Cite this article:
QU N, FANG X, ZHANG J, et al. Macro electrochemical milling and its hybrid variants. Chinese Journal of Aeronautics, 2024, 37(8): 1-35. https://doi.org/10.1016/j.cja.2023.12.015

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Received: 12 August 2023
Revised: 18 September 2023
Accepted: 14 November 2023
Published: 14 December 2023
© 2023 Chinese Society of Aeronautics and Astronautics.

This is an open access article under the CC BY-NC-ND license (http://creativecommons.org/licenses/by-nc-nd/4.0/).
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