Researches of electrochemical machining of internal spiral duct with small diameter

The internal spiral duct could enhance the exchange efficiency greatly. In this study, fabrication of the internal spiral turbulator processed by micro-ECM is presented. The experimental system for electrochemical machining of the spiral duct and preparation of the shaped electrode are developed. The experimental system consists of electrolyte supply module, power supply unit and workpiece holding device. The shaped electrode is prepared by using ultraviolet curing-mask method. Considering of the fabrication of the spiral internal turbulator in ECM, parameters affecting the machining stability and removal rate of material are also analyzed, including the voltage, electrolyte concentration and flux. Results indicate the stability becomes worse with the increase of voltage, electrolyte concentration and decrease of flux. Material removal rate increases with the increase of these parameters. Appropriate parameters should be selected considering the different conditions during machining. The scope of proper parameters should be as follows: 9–10V voltage, 100–150g/L electrolyte concentration and 1.8–2.4L/min flux.