Traveling wire electrochemical machining is a promising approach for the fabrication of various metal parts. However, the straycurrent\nattack deteriorates the surface quality while it is employed to cut thick workpiece as a normal pulse or DC is used. In this\npaper, the characteristics of the stray-current attack in reciprocated traveling wire electrochemical machining are firstly identified,\nand special insulating methods are proposed to reduce the effect of the stray-current.The model of electric field is built. Both the\nsimulation and the experimental results illustrate that the stray-current attack can be reduced significantly by the proposed insulatingmethods.\nFinally, structures with fine surface quality on stainless steel 304 with thickness of 20mmwere successfully produced.
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