Abstract
The electrochemical arc machining (ECAM) process combines features of ECM and EDM by application of a pulsed voltage between a cathode-tool and anode-workpiece in a liquid electrolyte. The new process offers rates of metal removal as much as five and fifty times greater than ECM and EDM, respectively. The study reported in this paper explores some of the fundamental processes which occur during ECAM. Experimental apparatus was constructed to enable single pulse discharges to be studied. Results are presented for 200μs pulses between 2 mm diameter silver steel electrodes in NaNO3 and NaCl electrolytes over a gap range of 10 to 90μm. Four stages of electrical phenomena were distinguished within a pulse: (a) high frequency voltage and current oscillations, (b) high rate electrochemical action, (c) low rate electrochemical action, and (d) electrodischarge action. The relative durations of the electrochemical and discharge phases, respectively, increase and decrease with increasing gap width, and vary with electrolyte type and concentration. High speed photography with an image-converter camera was used to record the occurrence of both spark and arc discharge in an electrolyte.
Published Version
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