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Received 19 September 2014; Accepted 12 November 2014
Academic Editor: Bo Yu
Copyright © Hansong Li et al. This is an open access article distributed under the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.
Electrochemical machining is widely used in the processing of difficult-to-machine metal materials. And through-mask electrochemical machining is a very important technology in the processing array structure of difficult-to-cut metal materials. Traditional through-mask electrochemical machining always uses a photoresist as the mask. The production process of a mask is complicated, and the mask cannot be reused. In this paper, through-active-mask electrochemical machining to process array structure in difficult-to-machine metal materials was investigated. Compared with traditional electrochemical machining masks, a copper-clad laminate is used to make the mask by mechanical machining in through-active-mask electrochemical machining. Also, the mask does not stick together with the workpiece but covers the workpiece by mechanical compaction, so the mask can be reused. In order to ensure the mask is in close contact with the workpiece, we need to arrange many compaction circular cylinders within the flow channel.The influences on electrolyte flow of compaction circular cylinders were investigated. The distribution of the compaction circular cylinders affects the electrolyte flow state, thereby affecting the processing. By analyzing the electrolyte flow state for the different distributions of compaction circular cylinders, one can find the best distribution of compaction circular cylinders for the required processing.
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1. Introduction
Parts with groups of holes or dimple matrix are widely used in the industrial fields of aviation, electronics, automotive, and others, such as cooling air tubes and air conduct damper bushing in aero engines, raster in electron microscopes, and surface textures on piston surfaces [1-3]. Parts with groups of holes always have stringent requirements about consistent aperture and accurate distribution of holes. The processed material should not show deformation or residual stress. Most difficult-to-cut metal materials such as titanium alloys or nickel-based superalloys are difficult to achieve these requirements. In order to meet these requirements, many authors have proposed various methods. Mousavi et al. used a self-vibratory drilling head to drill small-diameter deep holes, enabling productivity to be improved by eliminating retreat cycles [4]....