Evolution of electrochemical finishing processes through cross innovations and modeling

Recent advances in precision technologies have put stringent demands on micro-/nano-surface finishing processes; they require hygienic surfaces that are free from lays and stresses induced by finishing processes. Over the last two decades, the so-called conventional electrochemical finishing processes working on the electrical, chemical and mechanical principles have been coupled with additional sources of energy like magnetic field, ultrasonic vibrations, etc. to enhance their capability. This review focuses on fundamental principles and controlling parameters of the ECF/ECP processes that have been developed through cross innovations. It encompasses a detailed classification of the processes, followed by their salient features and capabilities. Mathematical and empirical approaches for the modeling of the processes have been presented along with their key formulations. It is understood that the processes are available for specific work materials and surface geometries, and in specific applications. It is necessary to investigate the effects of work/tool interactions in the presence of additional sources of energies besides the usual parametric effect, and to develop comprehensive phenomenological models and simulations of the ECF/ECP processes.

► Discusses principles and parameter effects of ECP processes with cross innovations.
► Encompasses process classification, salient features and capabilities.
► Discusses mathematical/empirical modeling approaches with key formulations.
► Provides recommendations to model work/tool interactions in ECP processes.