Influence of Low-Level Voltage in Pulse ECM on Electrode Wear and Machining Accuracy

Abstract

It is well-known that using pulse voltage could improve the machining accuracy in ECM process. However, the tool electrode wear occurs under some machining conditions in pulse ECM. In order to acquire the high machining accuracy, a method to eliminate the electrode wear by raising the low-level voltage was proposed and the relation between the low-level voltage and the machining accuracy was experimentally investigated in this research. It was found that the low-level voltage of 2V could not only prevent the tool electrode wear, but also improve the machining accuracy and the machining speed. In addition to the low-level voltage, the influence of the pulse duty ratio on the tool wear, the machining speed and accuracy was investigated. It was found that the raised low-level voltage was also effective when the duty ratio was increased and the increased duty ratio itself reduced the tool electrode wear.