Recast layer removal of WEDMed surface by wire electrochemical finishing

To eliminate the recast layer on surface machined by multi-pass wire electrical discharge machining (WEDM), hence improving integrity, present paper proposed and investigated a new combined process of performing electrochemical (WECM) after WEDM same machine tool utilizing slight conductivity compound working fluid. A theoretical model based electric double Faraday’s law electrolysis was established to calculate feed rate for WECM finishing. Due exclusive film protection fluid, modified according experimental results under different electrolyte concentrations. Afterward, optimized applied guide experiments process. An concentration 1:5 used facilitate reaction. The showed that remaining could be completely removed at 10 µm/s, fine finish obtained. In addition, roughness part improved from 1.458 µm Ra 0.683 Ra.