Stationary electrochemical machining of long, narrow, high-precision grooves

This work develops and demonstrates a model (i.e. mathematical description and computer simulation) for cutting precision long, narrow grooves with an Electrochemical Machining (ECM) process. The model predicts the resulting cut. Prediction of the outcome substantially reduces trial and error development, thus allowing a more cost effective and perhaps a more robust implementation of the ECM process. With long, narrow grooves a complicating factor is the relatively small cross section of the electrolyte channel, given the depth of the electrode groove. The small cross section limits the volume of electrolyte flow available to dilute sludge accumulation and provide cooling capability.This paper describes the historical background, function, and justification of ECM processes. Difficulties of traditional machining processes which ECM handles to advantage are workpiece complexity, inaccessibility, and material hardness. ECM combines the roughing and finishing of traditional machining into one step with excellent repeatability and with little or no tooling wear.A model is demonstrated which can predict the cut resulting from a given electrode. A variation of finite element approach is used to model the various parameters of the electrode groove cross section as a function of position along the electrode. Real time results are shown via an animated computer graphics simulator.An experimental setup has been developed which allows various electrode configurations to be tested. Ninety-six experiments were performed to verify the model's accuracy. Experimentation shows 0.01 mm (0.0004 inch) profile accuracy.