Abstract
Hybrid machining processes (HMPs) are gaining considerable attention from the manufacturing community in order to meet the challenges of stringent surface quality and tolerance requirements, often coupled with high production rates. This paper presents the experimental findings on the effects of key process parameters in controlling the surface micro-profile and correcting out-of-roundness (OR) in the electro-chemical honing (ECH) of internal cylinders. The results indicate that the current intensity, electrolyte concentration, segment out-pressure and segment grit size are the major contributing factors. A nano-finished surface featured with high uniformity of roughness values can be generated with precisely controlled out-of-roundness if a distinct co-ordination of electrolytic dissolution and mechanical abrading is achieved in ECH. Some key features of the indigenously developed ECH setup are also highlighted.
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