Abstract: In order to solve the problems in traditional machining of complex parts with thin wall such as nozzle, waveguide component and blade electrode in the fields of aeronautics and astronautics, a novel technique of free particles polishing electroforming with orbital movement cathode is put forward. Free particles are added between cathode and anode. The cathode moves with the orbital movement. The effect of periodic abrasion, polishing and squeezing of the free particles on the electro decomposition layer can improve the surface quality and strengthen the electroforming coating. In a comparison with the samples produced by traditional electroforming method, the free particles polishing electroforming is found to be able to obtain bright and smoothing surface. The intensity of (200) reduces and that of (111) and (220) increase significantly. The mechanical property of the coating is greatly improved due to the polishing and squeezing of the free particles. The micro hardness doubles and the tensile intensity increases by over 90%. Based on the experimental results, complex blade cathodes are produced successfully. Both micro hardness and surface roughness of the complex parts are improved significantly.

Key words: electroforming, abrasives, orbital movement, thin-walled parts, free particles