Modelling and Monitoring Interelectrode Gap in Pulse Electrochemical Machining

K. P. Rajurkar, B. Wei, J. Kozak, J. A. McGeough

Research output: Contribution to journalArticlepeer-review

104 Scopus citations


Pulse electrochemical machining (PECM) provides an economical and effective method for machining high strength, heat-resistant materials into complex shapes such as turbine blades of titanium alloys. The dimensional accuracy of PECM can be improved if a small interelectrode gap is maintained. This paper presents an interelectrode gap model for estimating machining parameters for the minimum gap size under the limit of electrolyte boiling. A specially-built PECM cell and a high speed data acquisition system are used to acquire the pulse current signal for developing an on-line monitoring strategy. A stochastic analysis of the current signal indicates a linear correlation between the gap size and the variance of the filtered current signal. An on-line monitoring system based on this correlation is proposed for the PECM process.

Original languageEnglish (US)
Pages (from-to)177-180
Number of pages4
JournalCIRP Annals - Manufacturing Technology
Issue number1
StatePublished - 1995


  • Accuracy
  • Electrochemical Machining
  • Modelling

ASJC Scopus subject areas

  • Mechanical Engineering
  • Industrial and Manufacturing Engineering


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