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<p>Electrochemical machining (ECM) is an established toolroom process used for various industrial applications. Numerous studies have been reported on the pulsed and non-pulsed modes of ECM to enhance surface characteristics. Additionally, significant studies have been reported on improving the performance of ECM by partially insulating the cathode with a floating inter-electrode slit (IES) or a fixed thermoplastic cathode cap (TCC), as modified electrochemical machining (MECM). However, little has been reported on the influence of pulsed mode in MECM with TCC to date. This study reports the effect of different sizes of TCC with varying internal cavity area (ICA) and outer cavity area (OCA) while pulsed and non-pulsed modes of MECM with Cu as a tool and Ti alloy as a workpiece (W/P) in terms of material removal rate (MRR) and surface roughness (Ra). In this study, for the pulsed mode, the pulse on time (T<sub>on</sub>) and off time (T<sub>off</sub>) were set to 100 × 10<sup>− 3</sup> s and 25 × 10<sup>− 3</sup> s, respectively, at an 8&#xa0;kHz frequency with an 80% duty cycle. The results suggest that the ICA of TCC and electrolyte flow rate are significant parameters for MRR and Ra, respectively, with the pulsed mode having an insignificant effect in MECM, contrary to ECM.</p>

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On modified electrochemical machining with a partial insulating cathode in pulsed and non-pulsed conditions

  • 期刊论文

  • 发表日期：

    2026年5月4日

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  • Arun Dutt Sharma,
  • Rupinder Singh,
  • Dixit Garg

摘要

Electrochemical machining (ECM) is an established toolroom process used for various industrial applications. Numerous studies have been reported on the pulsed and non-pulsed modes of ECM to enhance surface characteristics. Additionally, significant studies have been reported on improving the performance of ECM by partially insulating the cathode with a floating inter-electrode slit (IES) or a fixed thermoplastic cathode cap (TCC), as modified electrochemical machining (MECM). However, little has been reported on the influence of pulsed mode in MECM with TCC to date. This study reports the effect of different sizes of TCC with varying internal cavity area (ICA) and outer cavity area (OCA) while pulsed and non-pulsed modes of MECM with Cu as a tool and Ti alloy as a workpiece (W/P) in terms of material removal rate (MRR) and surface roughness (Ra). In this study, for the pulsed mode, the pulse on time (Ton) and off time (Toff) were set to 100 × 10− 3 s and 25 × 10− 3 s, respectively, at an 8 kHz frequency with an 80% duty cycle. The results suggest that the ICA of TCC and electrolyte flow rate are significant parameters for MRR and Ra, respectively, with the pulsed mode having an insignificant effect in MECM, contrary to ECM.