Modelling and analysis of pulse electrochemical machining (PECM)

J. Kozak, Kamlakar P Rajurkar, B. Wei

Research output: Contribution to journalArticle

49 Citations (Scopus)

Abstract

A small interelectrode gap in Electrochemical Machining (ECM) results in improved dimensional accuracy control and simplified tool design. However, using a small gap with conventional ECM equipment adversely affects the electrolyte flow or mass transport conditions in the gap, leading to process instability. The most remarkable breakthrough in this regard is the development of ECM using pulsed current. Pulse Electrochemical Machining [PECM) involves the application of a voltage pulse at high current density in the anodic dissolution process. PECM allows for more precise monitoring and control of machining parameters than ECM using continuous current. Small interelectrode gap, low electrolyte flow rate, gap state recovery during the pulse-off times and improved anodic dissolution efficiency features encountered in PECM lead to improved workpiece precision and surf ace finish when compared with ECM using continuous current. This paper presents mathematical models for the PECM process which take into consideration the nonsteady physical phenomena in the gap between the electrodes, including the conjugate fields of electrolyte flow velocities, pressure, temperature, gas concentrations, current densities and anodic material removal rates. The principles underlying higher dimensional accuracy and simpler tool design attainable with optimum pulse parameters are also discussed. Experimental studies indicate the validity of the proposed PECM models.

Original languageEnglish (US)
Pages (from-to)316-323
Number of pages8
JournalJournal of Manufacturing Science and Engineering, Transactions of the ASME
Volume116
Issue number3
DOIs
StatePublished - Jan 1 1994

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Machining
Electrolytes
Dissolution
Current density
Flow velocity
Mass transfer
Flow rate
Mathematical models
Recovery
Electrodes
Monitoring
Electric potential
Gases

ASJC Scopus subject areas

  • Control and Systems Engineering
  • Mechanical Engineering
  • Computer Science Applications
  • Industrial and Manufacturing Engineering

Cite this

Modelling and analysis of pulse electrochemical machining (PECM). / Kozak, J.; Rajurkar, Kamlakar P; Wei, B.

In: Journal of Manufacturing Science and Engineering, Transactions of the ASME, Vol. 116, No. 3, 01.01.1994, p. 316-323.

Research output: Contribution to journalArticle

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