Electrochemical drilling of multiple small holes with optimized electrolyte dividing manifolds

Abstract Structures with multiple small holes have been widely used to aid cooling in aeronautical engine components. Electrochemical drilling uses a side-insulated tube as the tool cathode and removes anodic material via controlled electrochemical reactions in a cell. The flexibility for simultaneous drilling makes electrochemical drilling a feasible technique for producing multiple small holes. In multiple hole electrochemical drilling, uneven electrolyte volume divided to each tube electrode would cause each hole machining status different. This paper addresses the design of an electrolyte dividing manifold for use in electrochemical drilling of multiple holes. Structural parameters such as the distance from the manifold inlet to the first tube electrode, the manifold inlet diameter and the tube electrode length have obvious effects on the electrolyte distribution along the electrode array. Experiments illustrate an optimized manifold structure is feasible for practical fabrication. Finally, two types of hole arrays are successfully fabricated.