Precision Electrochemical Machining

① The precision forming of three-dimensional cavities and free-form surfaces
adopts CNC cathode scanning and adaptive electrolyte flow field control technology to achieve precise replication and processing of three-dimensional structures such as turbine blade cooling film holes, complex mold cavities, and irregular flow channels. The surface contour accuracy is ≤0.01mm, the surface roughness Ra≤0.2μm, and there are no recast layers or microcracks.

② High-efficiency machining of micro-holes and irregular hole arrays:
It can process micro-holes with a diameter of Φ0.05-Φ2.0mm and a depth-to-diameter ratio (the depth-to-diameter ratio can reach 50:1), as well as square holes, conical holes, and irregular hole arrays. The verticality of the hole wall is ≥89°, and the hole opening is burr-free and rounded. It is suitable for precision parts such as fuel nozzles, screen plates, and heat exchangers.

③ Integrated molding of functional surface microtextures
: Through masking or scanning electrochemical processing, regular textures such as micropits, microgrooves, and cross grids are directly formed on the surface of parts. The feature size is 10-500μm and the depth accuracy is ±2μm, which can achieve specific functions such as friction reduction, anti-adhesion and enhanced heat transfer.

(2) Non-destructive processing technology for difficult-to-machine materials

① High-efficiency stress-free machining of high-temperature alloys and titanium alloys
: For difficult-to-machine materials such as Inconel 718 and Ti6Al4V, the principle of electrochemical anodic dissolution is used to achieve a material removal rate of 1-5 mm³/min. There is no mechanical stress or thermal stress during the machining process, and there is no heat-affected zone on the workpiece surface, thus maintaining the original mechanical properties of the material.

② Precision forming of cemented carbide and cermet:
Complex cavity machining of superhard conductive materials such as YG-type cemented carbide and cermet avoids the risk of chipping and cracking in traditional machining. The machining accuracy is ±0.005mm, the surface quality is excellent, and the service life of the mold is extended.

③ Deformation control of thin-walled and weakly rigid parts:
For thin-walled structures or slender weakly rigid parts with a wall thickness ≤ 0.2 mm, non-contact electrochemical machining can completely eliminate the deformation problem caused by cutting force, and the shape accuracy can be controlled within 0.01 mm.

① The multi-parameter adaptive closed-loop control system
integrates real-time monitoring and feedback adjustment of current density, electrolyte parameters, and inter-electrode gap. It automatically optimizes parameters such as voltage and pulse frequency according to the processing status to ensure processing stability and consistency. The dimensional dispersion of batch-produced parts is ≤ ±0.002mm.

② Multi-physics simulation optimization of the processing
: COMSOL and other software are used to perform coupled simulation of electrolyte flow field, electric field and temperature field, predict material removal profile and surface morphology, optimize cathode design and process parameters, reduce the number of trials and errors and improve the first-piece success rate.

③ Online visual monitoring and adaptive compensation
configuration: High-resolution endoscope and machine vision system are configured to observe the status of the processing area in real time. Combined with edge detection algorithm, the processing dimensions are measured online to realize automatic compensation and abnormal early warning of the processing process.

① Environmentally friendly electrolyte formula and recycling system:
We independently developed a low-concentration, low-corrosive, biodegradable special electrolyte system, combined with a high-efficiency filtration and regeneration system, to achieve an electrolyte recycling rate of ≥95% and reduce processing waste emissions by more than 80%.

② The active surface integrity control technology
can actively control the microstructure and chemical state of the processed surface by adjusting the pulse parameters and electrolyte composition, and can obtain mirror surface (Ra≤0.05μm), controllable roughness surface or specific chemically active surface.

③ Integrated surface passivation and protection after processing
: For materials such as stainless steel and titanium alloys, a dense passivation film is generated on the surface of the part in situ by adjusting the composition and potential of the electrolyte at the end of the processing stage, which improves corrosion resistance and reduces subsequent processing steps.