Optimization of Flying Wire Electrochemical Turning for High-Precision Micro Thin-Walled Component Machining

Micro thin-walled components play a critical role in precision machining fields, where high precision demands pose significant challenges to manufacturing technologies. This paper proposes a Flying Wire Electrochemical Turning (FWECT) process specifically tailored to the micro-machining needs of such components. The optimization of FWECT parameters aimed to enhance surface quality and material removal precision. A comprehensive analysis of various solutions' electrochemical characteristics identified sodium nitrate as the optimal electrolyte. The impacts of key process parameters, including rotation speed, pulse width, voltage, and feed rate, on material removal, machining overcut, surface roughness, and the radius of the machining end fillet were systematically investigated. A process parameter model was developed using Box-Cox transformation and statistical analysis, which was subsequently optimized to identify the best parameters for high-precision micro-machining. The optimized parameters were experimentally validated, successfully producing ultra-long tubular components with smooth transition fillets under stable operating conditions. This research significantly advances the application of FWECT in precision micro-machining, offering a robust foundation for future studies and practical applications in precision engineering.