PARAMETRIC CONTROL FOR OPTIMAL QUALITY OF THE WORKPIECE SURFACE IN ECM

The authors have successfully designed and developed an Electrochemical Machining set-up with a microprocessor-controlled stepper motor drive control unit for providing variable and automatic tool feed rates and also with an electronic circuit for auto-sensing of changes of the ECM gap condition during the course of machining, so as to actuate the auto-feedback control of the tool feed-rate and thus secure constant current Electrochemical Machining. The present paper also highlights various research results with the auto-feed ECM system for analysing the effect of some of the process variables, e.g. the electrolyte flow rate, the electrolyte concentration, the current density and the applied voltage, on the various surface-roughness parameters and bearing properties of the machined surface, as measured with the help of a computerised Talysurf unit. The test results indicate clearly the optimal parametric combinations that are needed for enhanced metal removal and better surface finish and other surface topographical characteristics, with the present design of auto-tool-feed control. It is evident from the test results that the present study on ECM will be quite useful and a step forward for proceeding with further applied research for achieving effective utilisation of ECM in practice, with better surface-quality characteristics so as to meet the needs of modern manufacturing industry.