Controlling of metal removal thickness in ECM process

Electrochemical machining (ECM) offers the unique advantage of better accuracy and high surface integrity of hard-machined components. A new technique has been developed to utilize a simultaneously moving and rotating electrode to remove a specific amount of material from pre-machined holes and rods of hardened steel specimens. One of the electrodes was provided with two simultaneous movements, traverse speed and rotational speed. The electrolyte was pumped into the gap between the tool and the workpiece, through a matrix of fine holes distributed along one of the electrode surface. A mathematical model has been proposed for accurately estimating the thickness of the workpiece layer under different working conditions. Experimental results revealed that this technique could lead to the removal of a surface layer thickness up to 200 μ, which consequently classified this method as a super-finishing process. Finally, the results of the experiments and the simulation are compared with each other. The obtained results are an endeavour to enhance the controllability of the ECM process.