Electrochemical machining under orbital motion conditions

The range of practical applications of electrochemical machining (ECM) is l imited by relatively low machining accuracy, specially in cases of complica ted shapes. One of the major problems is the generation of spikes which del ay the accuracy of the process. The problem is strongly exaggerated if the tool includes multi-electrolyte holes. Moreover, additional machining proce sses will be needed to remove the resultant spikes. In the present work, to ol orbital motion has been proposed as a new technique to enhance the ECM a ccuracy and to eliminate the presence of the spikes. A special test rig has been constructed for the orbital motion process. A theoretical model has b een derived to predict the shape of the frontal zone, the, effective machin ing time and the effective feed rate. The obtained results are an endeavor to provide the ECM tool designer with useful information to enhance the pro cess accuracy. Furthermore, the results facilitate the utilization of the E CM process in die sinking and mold industry. The effect of the applied volt age, feed rate, and tool eccentricity on the spike formation are also prese nted. (C) 2001 Published by Elsevier Science B.V.