Computer simulation of Pulse Electrochemical Machining (PECM)

Pulsed Electrochemical Machining (PECM) involves the application of a voltage pulse at high current density in the Electrochemical Machining (ECM) process. PECM allows for improved monitoring and control of the machining process when compared with traditional, direct current ECM. PECM is also readily automated. The small inter-electrode gap, system rest states between voltage pulses, and low electrolyte flow rate encountered in PECM lead to improved precision and surface finish when compared with d.c. ECM. This paper develops a mathematical model for PECM and employs this model in a computer simulation of the PECM process. The reasons for improved accuracy of PECM versus direct current ECM are also discussed.