Effect of atomization amounts on electrical discharge ablation machining and electrochemical machining

Abstract

ABSTRACT This study investigated the impact of varying atomization amounts on composite machining involving both atomized electrical discharge ablation machining and electrochemical machining (EDAM-ECM). Additionally, this study examined the effects of different atomization amounts on the material removal rate, relative electrode wear rate, processing waveforms, surface roughness, surface morphology and elements, and the EDAM-to-ECM ratio. Moreover, a theoretical model for describing the material removal process in composite processing was developed. Furthermore, the effect of the ECM ratio on the processing results was quantitatively analyzed through the integration of statistical circuits with a formula for calculating recast layer thickness. The model was used to predict and select the optimal atomization amounts required to achieve recast layer removal during processing. The results revealed that at an atomization amount of 200 mL/min, 16.7% of the total material removal was attributable to ECM, indicating the successful removal of the recast layer. At this atomization amount, the fabricated sample maintained a machining precision of 0.02 mm.