Formation mechanism and elimination of the workpiece surface macro-defects, aligned along the electrolyte stream at electrochemical machining

Here we present experimental investigation results, which attest that at electrochemical machining (ECM), macro-defects (“jet defects”) aligned along the electrolyte stream lines can arise. A mathematical model based on cavitations theory is proposed for theoretical description of the forming of such macro-defects. A formal criterion enables estimation of “jet defects” arising possibility for different conditions of electrochemical machining. Some engineering recommendations concerning condition parameters and requirements for construction of the appliances and the electrode-tool in order to eliminate this undesirable phenomenon are also formulated. For conditions of the impulse electrochemical machining by a vibrating electrode-tool, an indirect inform signal, can offer timely identification of situations of the “jet defects”. It can be used by a process engineer-operator of the electrochemical machine or by an automatic control system during the machining process.