Abstract
In this study, a theoretical model about the conversion mechanism of material removal by electric arc electrochemical machining (EAECM) was derived. The limiting conversion rate of ECM-EAECM was measured on this basis. The current waveform, surface integrity, shape accuracy and process indexes during machining were measured and evaluated. The results showed that when the limiting conversion rate of ECM was exceeded, the material removal consisted of alternating effects of electric arc machining (EAM) and ECM. The proportion of EAM increased and the surface structure evolved into discharge defects, verifying the correctness of the theory. In addition, parametric crossover experiments were performed to clarify the degree of parametric response to EAECM modulation. Finally, the optimal combination of parameters resulted in a material removal rate of up to 5452 mm3/min, a relative electrode wear rate of 1.39 %, and a surface roughness of only 4.62 μm.
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