Abstract
This paper discusses the possibility of mechanical/electrochemical complex machining (CM) as a highly efficient, highly accurate, and environmentally benign process. The prototype of a desktop machine tool named “ion-controlling desktop machine tool” for CM was developed. This small machine tool can change the resistance of the processing liquid automatically to carry out simultaneous complex machining (STCM) and sequential complex machining (SQCM) on the same machine tool. STCM and SQCM provide high precision, high efficiency, and low environmental impact for difficult-to-machine materials and difficult-to-machine shapes such as molds. This paper introduces the specifications and functions of the machine tool. As an application of the machine tool, a CM process that is a combination of electrical and mechanical processes is demonstrated. A 16-μm wide rectangular groove is machined by a CM process combining electrochemical machining (ECM) and cutting SQCM. The advantages of the machine tool and CM is shown by comparing the mold machining process using the complex machine tool and the same process using conventional machine tools.
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