On high resolution bubbly flow generator for gas-mixed micro electrochemical machining

Electrochemical machining (ECM) is one of the most promising non-traditional machining methods, known for its advantages such as high processing speed, excellent surface quality, no tool wear, and the ability to process difficult-to-cut metal materials. This study proposes a novel electrolytic gas mixing method for the electrochemical micro machining process, which effectively enhances mixing control precision also maintain small device overall size. The process was investigated by using an electrolytic gas mixing device from both theoretical and experimental perspectives. The study focused on the simulation and experimental verification of physical fields related to bubble size, electrolyte flow rate, and electrochemical machining characteristics. The results indicate that the developed mixing method in this study achieves high resolution mixing ratio control, coupled with high response speed and uniform bubble size. In microslot electrochemical machining verification, the results show that using this mixing device under the same parameters can effectively enhances the depth processing capability, suppresses surface flow marks, and reduces surface roughness.