Monitoring and control of electrochemical machining (ECM)

K. P. Rajurkar, B. Wei, C. L. Schnacker

Research output: Contribution to conferencePaperpeer-review

1 Scopus citations


The main advantages of Electrochemical Machining (ECM) process, such as high material removal rates and smooth, damage-free machined surface are often offset by the poor dimensional control and process stability resulting from complex and stochastic nature of the interelectrode gap (IEG) states. Full economic utilization of ECM will be realized only when reliable dimensional and process control systems are developed. This paper presents an ECM control model based on the basic ECM dynamics that accounts for the dynamic nature of the ECM process. The state space methodology is applied to transform it into the control model applicable to an ECM control system based on a digital computer. The model verification and controller design are accomplished by the simulation. ECM current and voltage signals have been acquired using a specially-built data acquisition circuit. The signals are digitized and analyzed with an IBM PC. The frequency analysis of the signal leads to a better insight of the physical mechanism of the ECM process. A comprehensive review on the state-of-the-art ECM research and development efforts in the areas of spark and short circuit detection and IEG control is also included in the paper.

Original languageEnglish (US)
Number of pages19
StatePublished - 1990
EventWinter Annual Meeting of the American Society of Mechanical Engineers - Dallas, TX, USA
Duration: Nov 25 1990Nov 30 1990


OtherWinter Annual Meeting of the American Society of Mechanical Engineers
CityDallas, TX, USA

ASJC Scopus subject areas

  • Industrial and Manufacturing Engineering
  • Mechanical Engineering


Dive into the research topics of 'Monitoring and control of electrochemical machining (ECM)'. Together they form a unique fingerprint.

Cite this