Research Progress of Electrochemical Machining Technology in Surface Processing: A Review

Area of Science:

• Materials Science
• Manufacturing Engineering

Background:

• Traditional machining faces challenges with advanced materials.
• Electrochemical machining (ECM) offers advantages like no contact stress and independence from material hardness.
• ECM is ideal for high-precision applications demanding superior surface quality.

Purpose of the Study:

• To systematically review ECM applications, recent progress, and current challenges in surface processing.
• To classify ECM technology based on surface requirements: quality enhancement and material shaping.
• To identify future research directions for advancing ECM capabilities.

Main Methods:

• Review of existing literature on ECM for surface processing.
• Classification of ECM into surface quality enhancement and material shaping (macro- and micro-scale).
• Analysis of techniques including precise anodic dissolution control, hybrid electrochemical-mechanical actions, and pulse power supplies.

Main Results:

• ECM achieves nanoscale planarization, residual stress reduction, and uniform surface performance.
• Macro-scale ECM combines electrochemical dissolution with mechanical action for high MRR and micron precision.
• Micro-scale ECM utilizes advanced pulse supplies and designs for micro-nano features on hard-brittle materials.

Conclusions:

• Key ECM challenges include inter-electrode gap control, electrolyte environmental impact, and tooling degradation.
• Future research should focus on green processing, intelligent control, multi-scale strategies, and hybrid energy fields.
• Advancing ECM is crucial for meeting stringent surface requirements of next-generation advanced materials.