Research on electrochemical machining of array holes with 3D-printed array hollow electrode and neutral electrolytes

In response to the urgent demands for efficient and precise large-scale fabrication of array holes, this study focuses on electrochemical machining technology and aims to address two major challenges: the difficulty in fabricating array hollow electrodes and stray corrosion. Traditional single-point serial processing techniques are insufficient to meet the requirements of mass-producing array holes. This research presents a monolithically fabricated array of hollow electrodes through a selective laser melting (SLM) process. Experimental validation confirms their excellent electrical conductivity and efficient flushing performance, thereby overcoming the key challenges in batch production and high consistency. Concurrently, considering the electrochemical properties of stainless steel, a parameter optimization study is conducted on neutral composite electrolytes. The effects of electrolyte composition and processing parameters on material removal rate and radial overcut are evaluated. Combined with multiphysics simulation, the underlying mechanisms by which electrolyte pressure and current efficiency influence byproduct discharge and material removal are elucidated. Ultimately, based on the SLM-fabricated array hollow electrodes and neutral electrolytes, array holes are fabricated on a stainless steel workpiece.