In order to solve the problem of uneven gap distribution and flow pattern in complex parts with multi-stage internal cone hole electrochemical machining, a method computer simulation–assisted cathode design is proposed. The electric field models machining are established respectively, simulations different profiles carried out. When angle 2°, between workpiece reasonable, electrolyte uniform. W...

Electrochemical machining (ECM) has been increasingly recognized for the potential for machining, while the precision of the machined profile is a concern of its application. A process to erode a hole of hundreds of micrometers on the metal surface is analyzed in the current paper. A theoretical and computational model is presented to illustrate how the machined profile evolves as the time elap...

New trends and the effect of key factors influence the quality of the holes produced by ECM processes. Researchers developed a fuzzy logic controller by adding intelligence to the ECM process. Maintaining optimum ECM process conditions ensures higher machining efficiency and performance. This paper presents the development of a fuzzy logic controller to add intelligence to the ECM process. An e...

Abstract GH4169 super alloy has a wide application in the field of aeronautics and astronautics, order to realize high quality fast processing complex workpieces with electrochemical machining (ECM), we have studied dissolution characteristics composite electrolyte, explored rule influence on voltage, feed speed, electrolyte pressure for gap (SG), material removal rate (MRR) surface roughness (...

Electrochemical machining is widely used in biomedical, aerospace, automotive, and other fields. The development of electrochemical (ECM) restricted by many factors such as the difficulty preparing micro-electrode, large machined gap serious stray corrosion. In this paper, we present a method to fabricate micro-holes combining micro-graphite electrode with hollow structure. Firstly, sealed grap...

Electrochemical machining is one of the most effective methods in machining of hard and complex shapes. As a result, it is a very good candidate for inside rifle machining. In this paper the principles and mathematical modelling, the results of computer simulation and experimental investigations of electrochemical rifling tool are presented. From this point of view, a rifling tool in electroche...

Waste metals in the form of metal oxide (hydroxide) sludges are generated in significant amounts by the metal finishing industries, and their accumulations pose problems for disposal and challenges for recycle. The availability of technically feasible efficient separations of metals such as nickel, cobalt, chromium, cadmium, copper, tin, zinc, lead, manganese, molybdenum, and titanium from plat...

Electrochemical machining (ECM) is a preferred advanced process for Monel 400 alloys. During the machining, toxic nickel hydroxides in sludge are formed. Therefore, it becomes necessary to determine optimum ECM parameters that minimize presence (NP) emission while maximizing material removal rate (MRR). In this investigation, predominant parameters, such as applied voltage, flow rate, and elect...

Electrochemical machining (ECM) is a non-traditional technology that widely used in the manufacturing of key components aviation industry. The current efficiency defined as ratio observed amount dissolved metal to theoretical predicted from Faraday’s law. In ECM, curve relates dissolution rate anode material and density. Accurate measurement basis for shape prediction cathode tool design. Howev...

Ultra-precision products which contain a micro-hole array have recently shown remarkable demand growth in many fields, especially in the semiconductor and display industries. Photoresist etching and electrochemical machining are widely known as precision methods for machining micro-holes with no residual stress and lower surface roughness on the fabricated products. The Invar shadow masks used ...