Minimization of machining allowance in electrochemical machining

Electrochemical machining (ECM) provides one of the best alternatives for producing complex shapes in advanced materials used in aircraft and aerospace industries. However, the reduction of sludge and memory errors continue to be major challenges for industries in addressing waste generation and accuracy improvement. This study focuses on minimizing the material to be removed by predicting minimum machining allowance and improving the degree of localized dissolution. Experiments have been conducted to verify the prediction results on an industrial ECM system. The use of pulse current with passivating electrolyte has been found to mitigate the sludge generation and improve accuracy.