Influence of currents density and gap size on metal removal rate and surface roughness in electrochemical machining (ECM)‎

Abstract EN

Electrochemical machining one of non traditional method whic h is used to machine a complex shape such as that uses the chemical reac tion associated with e le ctric current to remove metals.

In this study the ECM was used to remove the metals from the inte rnal hole of the workpiece (me dium carbon steel) by immersing it in electroly t e (250g of NaCl for eve ry litter ofH2O) with tool is made of brass.

The,m research focuses on the effect of the change in gap dimensions and the c urrents density on the metal removal rate (MRR) and surface roughne ss of the workpiece the results obtained show that increasing of gap size betwe en the tool and the workpiece from (1 to 3mm) leads to increase the surface roughness (46%) and while the material removal rate (MRR) dec reases (16%) at a current density (2.856 Amp/cm 2 ).

Also increasing of the current density from (2.4485 to 3.6728 Amp/cm 2 ), the surface roughness of the workpie ce dec re ases (31%) while the Material Removal Rate (MRR) increase s (93.9%) at a gap size of (1mm).