Selected problems of micro-electrochemical machining

The results of theoretical and experimental investigations of the relationship between the characteristic shape dimensions imported upon the anode-workpiece surface by the micro-features of the cathode-tool electrode under given machining conditions are presented. This research included the study of electrochemical copying of slots, mini-holes, grooves and insulating groove features. The limiting conditions of micro-ECM are considered from the point of view of copying and micro-shaping using non-profiled tool electrodes. For improving micro-machining capabilities of ECM processes, the application of ultra-short pulse current and ultra-small gap size is recommended. The results of investigation of pulse micro-ECM using non-profiled electrodes are also discussed in the paper.