Modelling the performance of ECM assisted by low frequency vibrations

The practical application of electrochemical machining (ECM) is still limited because of its lack of accuracy, difficulty of proper tool design and insufficient control of the operating parameters. Application of low frequency vibration to the tool electrode in electrochemical machining is one of the effective techniques for improving accuracy and quality of the machined surface. This paper presents an analytical approach to establish mathematical model in an endeavor to asses the mechanism of metal removal for this novel and hybrid technique. The effect of input parameters and machining conditions on the effectiveness of tool vibration during ECM has been fully investigated. The analytical model reveals that there could be a great complexity in the relationship between the tool amplitude and the equilibrium gap size, which could lead to tool damage, if the problem has not been carefully considered.