Optimization and Experimental Study of The Cathode in Array Microchannel Copy Electrochemical Machining

The processing quality of the array microchannels, as a critical component structure of the metal bipolar plates of fuel cells, has an important impact on the performance of fuel cells. Due to the high efficiency and quality of electrochemical machining (ECM), it is often used to process array microchannels. Traditional array microchannel electrochemical machining only considers factors such as stray corrosion or flow fields, while very little is optimized for the cathode. This paper set four cathode spacings (0.6 mm, 1.0 mm, 1.4 mm, 1.8 mm). The profile morphology of the array microchannels with different cathode spacings was compared by simulation combined with experiments. The cathode spacing of 1.4 mm was found to have the lowest stray corrosion intensity and the highest processing quality in the non-machined area of the microchannels.