Some Problems of Surface Roughness in Electrochemical Machining (ECM)

Electrochemical Machining (ECM) provides an economical and effective method for machining high strength, heat-resistant materials into complex shapes such. ECM is performed without physical contact between the tool and the workpiece in contrast to the mechanical machining. Therefore, surface layer formed during ECM process characterizes with no mechanical distortion, compressive stresses, cracks or thermal distortions.This paper presents some features of ECM processes, such as the effect of heterogeneous structure of material workpiece and the influence hydrodynamic instability of anode boundary layer on the surface roughness. A mathematical model was developed to simulate the evolution of surface profiles during electrochemical machining of alloys with the heterogeneous structure. Results of computer simulation and an analysis of the effects of various ECM factors and the structure of the workpiece material, on the of surface roughness and its parameters is done. The experimental investigations confirmed the effect of hydrodynamic instability of boundary layer on micro topography of machined surface done.