Experimental investigation of the effects of dedicated electrochemical machining parameters on freeform surface machining

Demirtas H., YILMAZ O., Kanber B.

JOURNAL OF MANUFACTURING PROCESSES, vol.43, pp.244-252, 2019 (SCI-Expanded) identifier identifier

  • Publication Type: Article / Article
  • Volume: 43
  • Publication Date: 2019
  • Doi Number: 10.1016/j.jmapro.2019.05.030
  • Journal Indexes: Science Citation Index Expanded (SCI-EXPANDED), Scopus
  • Page Numbers: pp.244-252
  • Keywords: Electrochemical machining (ECM), Freeform surface, Feed rate, Electrical conductivity, Dimensional error (DE), DESIGN, LAYER
  • Gazi University Affiliated: Yes


Electrochemical machining (ECM) is one of the most efficient non-traditional machining processes used to provide a bright surface finish, machine difficult-to-cut materials and manufacture complex shapes. However, due to some challenges, such as the lack of dimensional accuracy, process monitoring and control and environmental factors, implementation of the ECM process has been limited. This study presents the effects of two dedicated ECM parameters, feed rate and electrical conductivity of the electrolyte, on freeform surface machining. Nine different cathodes are designed in accordance with the dedicated parameters, important variables for cathode design. A 3D scanner is used to measure and then compare the electrochemically machined anode surfaces with a computer-aided design (CAD) model. The experimental machining-depth distance of the cathode (in the z dimension) is 2 mm. Dimensional error (DE) values are used to discuss the effect of the ECM parameters on dimensional accuracy. It is observed from the scanned 3D machined surfaces that higher electrical conductivity combined with higher feed rate produced a more accurate shape. Machining error rates (MERs) decreased from -21.8% to -16.3% for over-machining rates and from 20.45% to 7.2% for non-machined rates, with an increase of electrical conductivity from 50 to 100 mS/cm, respectively. In addition, the experiments demonstrated that the feed rate does not affect the MERs at the lowest electrical conductivity value (50 mS/cm).