Macro electrochemical milling and its hybrid variants

Macro electromechanical milling has recently attracted increasing attention because numerous large thin-walled structures composed of difficult-to-cut materials are employed in the aerospace field. This paper reviews recent developments in state-of-the-art macro electromechanical milling. The fundamental aspects of material removal mechanisms, such as the generation and breakdown behaviors of passive oxide films of typical difficult-to-cut materials, were discussed. Rapid methods for breaking down passive films are summarized, and simulation methods for the machining process coupling multiple physical fields are introduced. Specific electrochemical milling methods, including fly mode electrochemical milling and sink electrochemical milling, are classified. Efforts made to improve process performance, such as the material removal rate, surface quality, and machining accuracy, are discussed. In addition, the main hybrid electrochemical milling methods, including electrochemical discharge milling, mechano-electrochemical milling, and electrochemical mill grinding, are also presented.