Metal gratings with rhombus holes are widely applied in lightweight aircraft components. Electrochemical machining (ECM) is a nontraditional processing technology with no tool loss and no thermal deformation that has unique advantages for the high-quality processing of rhombus holes. However, the flow paths of the electrolyte in the lateral gap are quite different, and stray corrosion easily occurs on the sidewall due to the different diagonal lengths of a rhombus hole. In this paper, a method was proposed to improve the flow field and processing localization by the synchronization of the pulse power supply and low-frequency oscillations. The on and off positions of the pulse power supply are symmetrical with respect to the wave trough of the oscillation waveform. Based on the coupled simulation of the gas-liquid two-phase flow field and electric field, the effects of assisting oscillations and synchronization of the pulses and oscillations on the void fraction, electrical conductivity, current density, dissolution rate and evolution of the anode profile were investigated. Moreover, the effects of assisting oscillations and synchronization of the pulses and oscillations on the lateral gap, sidewall slope, machining fillet and surface quality were experimentally studied. The experimental results of different ECM methods showed that the coupled simulation was effective and feasible. Moreover, the simulation analysis and experimental results both revealed that the processing accuracy and surface quality of a rhombus hole could be improved by using the synchronized ECM method. The lateral gap at the rhombus hole entrance was only 0.13 mm, the sidewall slope was 0.026 and the surface roughness was R_a0.134 μm under the optimized parameters.

带有菱形孔的金属格栅广泛应用于轻型飞机部件。电化学加工（ECM）是一种非传统的加工技术，无工具损耗且无热变形，对于菱形孔的高质量加工具有独特的优势。然而，电解质在横向间隙中的流动路径完全不同，并且由于菱形孔的对角线长度不同而在侧壁上容易发生杂散腐蚀。本文提出了一种通过同步脉冲电源和低频振荡来改善流场和处理局部化的方法。脉冲电源的接通和断开位置相对于振荡波形的波谷对称。基于气液两相流场和电场的耦合模拟，辅助脉冲和振荡的振荡和同步对空隙率，电导率，电流密度，溶解速率和阳极分布的影响被调查了。此外，实验研究了辅助振荡以及脉冲和振荡的同步对横向间隙，侧壁斜率，加工圆角和表面质量的影响。不同ECM方法的实验结果表明，耦合仿真是有效可行的。仿真分析和实验结果均表明，采用同步ECM方法可以提高菱形孔的加工精度和表面质量。在优化参数下，R _a为0.134μm。