Experimental study on effect of machining parameters on machining characteristics and surface morphology in ECM

In this study, relationship between effect of machining parameters on machining characteristics and surface morphology was studied in electrochemical machining (ECM). The characteristics were Material Removal Rates (MRR), Over Cut (OC), Surface Roughness (SR) and surface morphology. The results show that MRR is increased by increasing current but OC is decreased. Increasing concentration causes to increase MRR, OC and SR. Also, the analysis of surface morphology shows that the electrolyte type affects the dissolution mechanism and surface layer formation in ECM. There are cavities in NaCl and KCl that their diameter, depth and distribution on the machined surface are changed by parameters and their diameters were ۴μm to ۹μm. Increasing ion concentration causes to enhance the diameter size and depth of created cavities on work piece but their uniform distribution decreases, while the current has a reverse effect on them. On the other hand, an oxide layer is formed on the machined surface in NaNO۳ and by increasing current and concentration, breaking and the anion cavity effect are increased on this layer. So, increasing the MRR and SR is due to this phenomenon in NaNO۳.

کلیدواژه ها:

Electrochemical machining (ECM) ، Oxide layer ، Machining characteristics ، Surface morphology ، Surface cavity effect