Electrochemical, Electrodischarge and Electrochemical-discharge Hole Drilling and Surface Structuring Using Batch Electrodes

Abstract

According to the rapid development of new materials, and requirements of the industrial sector towards effective and efficient machining of holes with diameters smaller than 1mm, recent researches in the field of machining processes are aimed at investigations and optimization machining processes using multiple tools, multi-electrodes. Effective methods of machining difficult to cut materials are non-contact machining methods of electrochemical (ECM), electrodischarge (EDM) and hybrid electrochemical-discharge machining (ECDM). Both processes incorporating electrochemical dissolution, characterise with high material removal rates. They also do not induce high electrode wear ratios.In this paper, the results of experiments in the field of ECM, EDM and ECDM machining processes using batch electrodes will be presented. Batch electrodes used in the presented study consist of 9 square working tips of 2x2mm, enabling flushing of the electrolyte through the electrode tip. Electrodes are prepared using additive manufacturing method – Selective Laser Sintering (SLS). The paper focuses on performance characteristics of machining processes for various materials used in the aircraft and plastic industry. There is also discussed (basing on the experimental results) influence of the working media supply method to the machining area (submerged or flushing) on the: machining accuracy, material removal rate and influence of stray currents on the surface of machined material. In the paper there is also presented comparison of results of various methods of contactless machining with tool electrodes prepared of using subtractive and additive manufacturing method. The comparison concerns machining time, machining accuracy and time necessary for manufacturing of tool electrodes.