Abstract: In order to enhance the processing stability and machining accuracy of electrochemical drilling (ECD) on multiple holes, the flow of the electrolyte along the dividing manifold is modeled, and the electrolyte distribution along the dividing manifold is analyzed through the numerical solution of the model. Manifold diameter, which is the main parameter affecting the uniformity of electrolyte distribution, is optimized subsequently. Based on the optimization, experiments are conducted to obtain the uniformity ratio and the corresponding dimension ratio which suit the multiple hole drilling process. With optimized manifold structure and suitable machining parameters, long rows of holes with a spacing of 5 mm and a diameter of (1.03±0.03)mm are machined by multiple electrodes with good stability. Flow uniformity can be enhanced by optimizing the manifold structure, the machining stability and accuracy of ECD process is hence increased.

Key words: electrochemical cutting, stability, manifolds, optimization, electrochemical drilling