In the macro electrochemical jet milling, the surface quality produced by the standard cathode tool is unsatisfactory owing to the inevitable effects of low current density and inefficient mass transfer. This paper proposes a novel cathode tool with an insulated nozzle tip and inclination angle to confine the low current density area and enhance the mass transfer. The theoretical analysis and numerical simulation results reveal that the designed tool with an inclined angle helps to increase the flow velocity of electrolyte in the machining gap and reduces the effect of the low current density during the machining process. Experimental results show that the surface roughness produced by the proposed tool (tool C) is reduced by approximately 6 times compared with the standard tool. Furthermore, the material removal rate of tool C is approximately 1.6 times equal to that of the vertical mode. Besides, a mirror-like surface with a clear reflection and surface roughness (Ra) of 0.12 µm was successfully fabricated.

在宏观电化学喷射铣削中，由于电流密度低和传质效率低下的不可避免的影响，标准阴极工具产生的表面质量不能令人满意。本文提出了一种具有绝缘喷嘴尖端和倾斜角的新型阴极工具，以限制低电流密度区域并增强传质。理论分析和数值模拟结果表明，所设计的倾斜角度刀具有助于提高加工间隙中电解液的流速，减少加工过程中低电流密度的影响。实验结果表明，与标准刀具相比，所提出的刀具（刀具 C）产生的表面粗糙度降低了约 6 倍。此外，刀具 C 的材料去除率约为 1。相当于垂直模式的6倍。此外，成功地制造了具有清晰反射和表面粗糙度（Ra）为0.12 µm的镜面表面。