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<p>Electrochemical discharge machining (ECDM) has received considerable attention in aerospace and precision manufacturing. Because ECDM involves combined electrochemical machining (ECM) and electrical discharge machining (EDM) effects, it is difficult to understand the influence of different energy distribution states on ECDM results. In this study, we investigated the effects of different ECDM energy distributions and surface morphology based on the theory of heat transfer and phase change. By solving the movement equation of the phase change interface and considering it as the material removal rate (MRR) equation caused by EDM energy, the equation was coupled with the MRR equation of ECM to establish an energy distribution model. Additionally, the energy distribution coefficient (Edc) of the energy distribution model was calculated by analyzing the experiment electrical signals. The results of different surface morphologies and Edc were also compared and analyzed, and the changes were consistent with these results. Finally, we validated the energy distribution model, which exhibits high application potential in ECDM.</p>

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Energy distribution mechanisms in electrochemical discharge machining: a combined theoretical and experimental investigation

  • 期刊论文

  • 发表日期：

    2025年8月18日

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  • Lu Wang,
  • Xiaoyun Hu,
  • Jinhao Wang,
  • Hansong Li

摘要

Electrochemical discharge machining (ECDM) has received considerable attention in aerospace and precision manufacturing. Because ECDM involves combined electrochemical machining (ECM) and electrical discharge machining (EDM) effects, it is difficult to understand the influence of different energy distribution states on ECDM results. In this study, we investigated the effects of different ECDM energy distributions and surface morphology based on the theory of heat transfer and phase change. By solving the movement equation of the phase change interface and considering it as the material removal rate (MRR) equation caused by EDM energy, the equation was coupled with the MRR equation of ECM to establish an energy distribution model. Additionally, the energy distribution coefficient (Edc) of the energy distribution model was calculated by analyzing the experiment electrical signals. The results of different surface morphologies and Edc were also compared and analyzed, and the changes were consistent with these results. Finally, we validated the energy distribution model, which exhibits high application potential in ECDM.