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<p>This study investigates the effects of novel electrolysis gas-mixed electrolyte and sequential pulse power supply on electrochemical machining (ECM) performance. The research aims to enhance machining efficiency and precision by leveraging improved electrolyte renewal and optimized pulse parameters. Experimental analyses were conducted to evaluate the impact of pulse width, frequency, and electrolysis gas-mixing conditions on surface quality and material removal rate (MRR). Results indicate that higher pulse frequencies increase machining gaps, enhancing material removal but affecting surface roughness. Additionally, electrolysis gas-mixed electrolytes significantly improve electrolyte flow and decrease polarization effects, thereby optimizing machining performance. Computational fluid dynamics (CFD) simulations confirm that gas inclusion enhances electrolyte renewal rates, reducing machining by-products’ adverse effects. These findings provide insights into improving ECM efficiency without increasing equipment complexity.</p>

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Enhancing electrochemical machining performance by electrolysis gas mixing electrolyte combined with sequential pulse power supply control system

  • 期刊论文

  • 发表日期：

    2025年8月29日

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  • Po-Jen Yang,
  • Jung-Chou Hung

摘要

This study investigates the effects of novel electrolysis gas-mixed electrolyte and sequential pulse power supply on electrochemical machining (ECM) performance. The research aims to enhance machining efficiency and precision by leveraging improved electrolyte renewal and optimized pulse parameters. Experimental analyses were conducted to evaluate the impact of pulse width, frequency, and electrolysis gas-mixing conditions on surface quality and material removal rate (MRR). Results indicate that higher pulse frequencies increase machining gaps, enhancing material removal but affecting surface roughness. Additionally, electrolysis gas-mixed electrolytes significantly improve electrolyte flow and decrease polarization effects, thereby optimizing machining performance. Computational fluid dynamics (CFD) simulations confirm that gas inclusion enhances electrolyte renewal rates, reducing machining by-products’ adverse effects. These findings provide insights into improving ECM efficiency without increasing equipment complexity.