Abstract

Electrochemical machining (ECM) principally enables a highly productive and virtually wear-free production of components with simultaneously high surface quality. However, the process generates changes concerning both the geometry as well as the rim zone of manufactured components, so that the entire process design currently runs through several heuristic cycles. As a result, the cost-effectiveness of the process is often only given in large-scale production. The paper therefore mechanistically links the material modifications and the process-induced material loads for electrochemical processes to predict rim zone properties. Inverted components of the resulting process signature can finally be used for virtual process design.

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