Pillar arrays on metallic surfaces gain important applications in industry, however the machining of them still remains great challenges for conventional methods. In this paper, counter-rotating electrochemical machining (CRECM) using a small cathode tool with multiple hollow windows was proposed to fabricate intensive cylindrical pillar array on revolving surface. The cathode tool was designed on basis of the anode shaping process in CRECM. The results indicated that in order to obtain desired circular pillar structures, the hollow windows on the cathode tool should be designed to be non-circular shapes and their sidewalls needed to be electrically insulated. These multiple specific-designed hollow windows bring challenges for conventional methods.

To machine the specific-designed cathode tool, a novel hybrid additive manufacturing process combining 3D printing and electrodeposition was presented. A cylindrical cathode tool with multiple non-circular insulating hollow windows was successfully fabricated through electrodeposition on a 3D printed base part with partial conducive treatment. CRECM experiment of intensive pillar array was conducted using the additive manufactured cathode tool. An intensive (60 × 7) cylindrical pillar array with average dimensions of 4.3 mm diameter and 2.4 mm height was machined on the revolving surface. The profiles of different pillar structures exhibited favorable uniformity.

金属表面上的柱状阵列在工业中获得了重要的应用，但它们的加工仍然是传统方法的巨大挑战。在本文中，提出了使用具有多个空心窗口的小型阴极工具的反向旋转电化学加工（CRECM）在旋转表面上制造密集的圆柱柱阵列。阴极工具是根据 CRECM 中的阳极成型工艺设计的。结果表明，为了获得所需的圆柱结构，阴极工具上的中空窗口应设计为非圆形，其侧壁需要电绝缘。这些多个专门设计的空心窗给传统方法带来了挑战。

为了加工特定设计的阴极工具，提出了一种结合 3D 打印和电沉积的新型混合增材制造工艺。通过在部分导电处理的 3D 打印底座上进行电沉积，成功制造了具有多个非圆形绝缘中空窗口的圆柱形阴极工具。使用增材制造的阴极工具进行密集柱阵列的 CRECM 实验。在旋转表面上加工出平均直径为 4.3 毫米、高度为 2.4 毫米的密集（60 × 7）圆柱柱阵列。不同柱结构的轮廓表现出良好的均匀性。