Abstract
Pulse electrochemical machining (PECM) provides an economical and effective method for machining high strength, heat-resistant materials into complex shapes such as turbine blades of titanium alloys. The dimensional accuracy of PECM can be improved if a small interelectrode gap is maintained. This paper presents an interelectrode gap model for estimating machining parameters for the minimum gap size under the limit of electrolyte boiling. A specially-built PECM cell and a high speed data acquisition system are used to acquire the pulse current signal for developing an on-line monitoring strategy. A stochastic analysis of the current signal indicates a linear correlation between the gap size and the variance of the filtered current signal. An on-line monitoring system based on this correlation is proposed for the PECM process.
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