Abstract
The current work investigates the improvement of surface finish of external cylindrical surface finish on several die materials beyond traditional rough turning or drawing by electropolishing using arrowhead electrodes. The electrode is designed effective and low-cost. The controlled factors in electropolishing test include the chemical composition and concentration of the electrolyte, the electrolyte temperature, the flow rate of electrolyte, and the initial gap width. The experimental parameters are die material, rotational speed of workpiece and tool electrode, current rating, the electrode design parameters, and electrode feed rate. The electrode travels across the surface with continuous direct current. Both cone and flat arrow-head features are studied. Small end radius and high rotational speed of electrode produce good polishing. Small end radius also leads to high current density and feed rate. Small taper angle and large flute rake angle provide sufficient discharge space, which is advantageous for electropolishing. The electrode with double discharge flutes is superior to the electrode with single flute. Thin electrode with large flute rake angle and deep flute performs well.