The inverse or cathode shape design problem of electrochemical machining (ECM) deals with the computation tool required for producing a workpiece anode desired shape. This work applied complex variable method and continuous adjoint-based optimization to solve steady-state shapes different smoothnesses. An exact solution is proven exist only in cases when function describing analytic. solution’s...

Considering exponential dependence of currents on double-layer voltage and the feedback effect of the electrolyte resistance, a distance effect in electrochemical micromachining is found, namely that both time constant and double-layer voltage depend on the separation of electrodes. The double-layer voltage is the real voltage used in processing. Under DC voltage, the apparent voltages between ...

Formation of spikes prevents achievement of the better material removal rate (MRR) and surface finish while using plain NaNO3 aqueous electrolyte in electrochemical machining (ECM) of die tool steel. Hence this research work attempts to minimize the formation of spikes in the selected workpiece of high carbon high chromium die tool steel using copper nanoparticles suspended in NaNO3 aqueous ele...

Niobium carbide (NbC) is a high hardness 1960 (HV30) cermet material which finds applications in the moulds for ceramic injection moulding as well inserts cutting tools. This possesses excellent combination of hardness, toughness and thermal shock resistance. The use nickel (Ni) binder makes it promising such applications, especially view rising cobalt (Co) metal prices used conventional tungst...

Electrochemical spark machining (ECSM) is hybrid machining process which is the controlled removal of metal by anodic dissolution as well as erosion in an electrolytic cell in which the workpiece is the anode and the tool is cathode. The experimental investigation with the developed TW-ECSM set-up has been needed to understand the behaviour of the process parameters on performance characteristi...

Performance criteria namely Material Removal Rate (MRR), Surface Roughness (SR) and Radial Over Cut (ROC) in electrochemical machining process greatly affected by the machining parameters like electrical parameters, electrode parameters, electrolyte parameters and workpiece properties. In the present work applied voltage (electrical parameter), tool feed rate (electrode parameter), electrolyte ...

in the present study, five modeling approaches of ra, mlp, mnn, gff, and canfis were applied so as to estimate the radial overcut values in electrochemical drilling process. for these models, four input variables, namely electrolyte concentration, voltage, initial machining gap, and tool feed rate, were selected. the developed models were evaluated in terms of their prediction capability with m...

Some conventional machining methods have been developed to machine microelectrodes. However, these methods still require too much time and too many resources. This paper uses electrochemical etching as an alternative method for the simple and cheap fabrication of microelectrodes. Electrochemical etching is usually considered an appropriate method of producing sharp probes. However, it is possib...