INCLINED, SPIRAL ELECTROLYTE JETS IN A ROTATING TOOL IMPROVE ELECTROCHEMICAL MACHINING PERFORMANCE

摘要

Electrochemical Machining (ECM) is a method of removing metal by controlled anodic dissolution process of the work piece with the tool in an electrolytic cell, during an electrolysis process. ECM is an electrochemical process in which a direct current with high density and low voltage is passed between a work piece and a pre shaped tool (the cathode). At the anodic work piece surface, metal is dissolved into metallic ions by the depleting reaction, and thus the negative mirror shape of tool is reproduced into the work piece. Electrochemical machining has established itself as one of the major alternatives to conventional methods for machining hard materials and complex contours without the residual stresses and tool wear. Studies on Metal removal rate (MRR) and Surface finish are of utmost importance in Electrochemical machining, since it is the important factors in the process decisions. Usually, research reports say,, electrolyte of NaCI aqua solution allows a higher metal removal rate, but from the point of accuracy, to apply NaN03 aqua solution (electrolyte) is better. This work claims the effect of jets configurations on the metal removal rate (MRR) and surface finish. The experiments were conducted by using various electrolyte jet configurations and the results proved that better MRR and surface finish have been achieved by directing NaCI aqua solution through the Inclined (inward) jets in spiral pattern (electrolyte opening configuration) in the rotating tool setup at 2 rpm. So the electrochemical machining process has obviously improved.