Electrochemical Machining (ECM) plays an important role in the manufacturing of core components of aerospace equipment. To meet the development demands of these high-tech products, the machining accuracy of ECM needs to be further improved. During ECM process, hydrogen bubbles, joule heat and machining products are generated, which remarkably affects the distribution of the electrolyte conductivity in the inter-electrode gap and reduces the machining accuracy. Pulse dynamic ECM effectively change the gap state and improve the machining accuracy and stability by coupling tool vibration with pulse machining current optimally. In this paper, three kinds of pulse dynamic ECM modes containing copy-like ECM, counter-rotating ECM and wire ECM with edged electrode are proposed, which present favorable process effects on the machining of complex structures such as engine blades, casings and tenon grooves.
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