Development of Horizontal Vibration-Assisted Pulsed Electrochemical Machining System

Abstract

This research aims to understand flushing of byproducts between the anodic workpiece and the cathodic electrode in the electrochemical machining (ECM) process. The ion transport mechanism between the inter-electrode gaps under low vibration frequency applied on the workpiece has been theoretically analyzed and simulated. A series of holes have been machined on a 1018 steel plate by the presented device to evaluate the effects of vibration on machining depth and taper angle. Mathematical model and simulation model for ion transport between the anodic workpiece and the cathodic electrode were developed to illustrate the effects of vibration frequency on by-products’ average flushing speed between the inter-electrode gaps. The results showed that the maximum machining depth (1584 μm) and the minimum taper angle (16.57°) achieved at 40 Hz vibration frequency and 10 μm vibration amplitude. Meanwhile, the simulation results showed that the maximum average flushing speed (0.3968 m/s) were obtained at this vibration frequency and vibration amplitude. There is a positive/negative correlation between the average flushing speed and machining depth/taper angle.