Abstract
This paper presents results of experimental investigation carried out to develop quantitative relationships for inter-electrode gap and surface characteristics in Electrochemical Machining (ECM). The effect of grain size on the machining gap and, therefore, on the ECM performance and tool design is discussed. The wavelength decomposition of surface profiles and current signals have been carried out with a view to develop a better understanding of surface generation and random occurrences of sparking in ECM respectively. The dynamics of ECM process is modeled in state space notation and the adequacy of the model has been verified by simulation.
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