Monitoring and control of electrochemical machining (ECM)

K. P. Rajurkar, B. Wei, C. L. Schnacker

Research output: Contribution to journalArticle

1 Citation (Scopus)

Abstract

The main advantages of the electrochemical machining (ECM) process, such as high material removal rates and smooth, damage-free machined surface, are often offset by the poor dimensional control and process stability resulting from the complex and stochastic nature of the interelectrode gap (IEG) states. Full economic utilization of ECM will be realized only when reliable dimensional and process control systems are developed. This paper presents an ECM control model based on the basic ECM dynamics that accounts for the dynamic nature of the ECM process. The state space methodology is applied to transform it into the control model applicable to an ECM control system based on a digital computer. The simulations have been made for the model verification and controller design. A new approach is introduced to develop an indicator that detects or predicts the onset of random sparks based on ECM current signal analysis. ECM current and voltage signals have been acquired using a specially-built data acquisition circuit. The signals are digitized and analyzed with an IBM PC. The frequency analysis of the signal leads to a better insight of the physical mechanism of the ECM process. A comprehensive review of the state-of-the-art ECM research and development efforts in the areas of spark and short circuit detection and IEG control is also included in the paper.

Original languageEnglish (US)
Pages (from-to)216-223
Number of pages8
JournalJournal of engineering for industry
Volume115
Issue number2
DOIs
StatePublished - Jan 1 1993

Fingerprint

Machining
Monitoring
Electric sparks
Control systems
Signal analysis
Digital computers
Short circuit currents
Process control
Data acquisition
Controllers
Economics
Networks (circuits)
Electric potential

ASJC Scopus subject areas

  • Engineering(all)

Cite this

Monitoring and control of electrochemical machining (ECM). / Rajurkar, K. P.; Wei, B.; Schnacker, C. L.

In: Journal of engineering for industry, Vol. 115, No. 2, 01.01.1993, p. 216-223.

Research output: Contribution to journalArticle

Rajurkar, K. P. ; Wei, B. ; Schnacker, C. L. / Monitoring and control of electrochemical machining (ECM). In: Journal of engineering for industry. 1993 ; Vol. 115, No. 2. pp. 216-223.
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