It is well known that the machining gap of conventional electrochemical polishing is usually set at 100-300 mm, but it is obviously impossible because of the size limitation of small diameter stainless steel square pipe. For this kind of small gap machining, the surface roughness of tool electrodes is different, and the processing gap between stainless steel square pipe and the points on the tool electrodes surface is also changed.
Machining clearance will directly affect the current density of the corresponding position. Where the gap is large, the current density is relatively low, the material removal rate is low, and the current density is relatively high in the small processing gap, and the material removal rate is high.
Therefore, the micro-geometry of tool electrode surface forms different replication degrees on polished stainless steel square pipe surface.