A shaver cap is a typical thin-walled rotational part, and the processing performance of its torus surface has an important impact on the cutting efficiency, sharpness and working noise of the shaver. Electrochemical face grinding (ECFG) is a promising machining method in the fabrication of difficult-to-cut thin-walled parts. However, the flow field distribution in the interelectrode gap can vary, and the effect of electrochemical levelling can suffer during the electrochemical face grinding of multiple torus surfaces. Moreover, the nonuniform distribution of abrasives and the differences in coequal height can generate severe grinding marks on the torus surfaces. In this work, superimposed linear and circular translational movements were proposed to improve the electrochemical grinding performance of multiple torus surfaces. Based on a simulation of a gas-liquid two-phase flow field, the effects of grinding head rotational speed and superimposed linear and circular translational movements on the flow velocity and void fraction were investigated. Moreover, the variations of machining allowance, flatness and surface roughness on the torus surfaces were experimentally studied. The flow field simulation and experimental results showed that the flow velocity and void fraction were changed periodically in the machining area by superimposing translational movements, which was conducive to eliminating flow field defects and improving the electrochemical levelling performance. Moreover, the fluctuations of electrolyte flow velocity and void fraction in the machining area were small when the circular translational movement was superimposed, and a synergistic effect of dissolution and grinding was noted. The overall flatness of the torus surfaces was only 3.93 μm, the maximum height of the surface roughness profile was 0.797 μm, and there were no obvious grinding marks on the inner and outer torus surfaces under the optimized circular translational parameters.

剃须刀帽是典型的薄壁旋转件，其环面的加工性能对剃须刀的切削效率、锋利度和工作噪音有重要影响。电化学面磨削 (ECFG) 是制造难切削薄壁零件的一种很有前途的加工方法。然而，电极间间隙中的流场分布可能会发生变化，并且在多个环面表面的电化学面磨削过程中，电化学整平的效果会受到影响。此外，磨料的不均匀分布和等高的差异会在环面表面产生严重的磨痕。在这项工作中，提出了叠加的线性和圆形平移运动，以提高多个环面的电化学研磨性能。在模拟气液两相流场的基础上，研究了磨头转速和叠加的线性和圆形平移运动对流速和空隙率的影响。此外，实验研究了环面加工余量、平面度和表面粗糙度的变化。流场模拟和实验结果表明，通过叠加平移运动，加工区域的流速和空隙率发生周期性变化，有利于消除流场缺陷，提高电化学整平性能。此外，当叠加圆形平移运动时，加工区电解液流速和空隙率的波动很小，并注意到溶解和研磨的协同作用。环面整体平整度仅为3.93 μm，表面粗糙度轮廓最大高度为0.797 μm，优化后的圆形平移参数下环面内外环面均无明显磨痕。