On the Modified Electrochemical Machining Process with a Partially Insulating Cathode

In the past three decades, several studies have reported the process parametric optimization of electrochemical machining (ECM). But hitherto little has been reported on the modified ECM with a partially insulating cathode (that alters the mechanism of replicating the tool profile) and may help in a tunable profile generation on a workpiece with the high aspect ratio required for the tool room process. This study outlines the performance of Al and Ti alloys both as an anode and partially insulating cathode in terms of metal removal rate (MRR), dissolution rate (DR), and other surface characteristics with selected input parameters in modified ECM. Based on scanning electron microscopy, %porosity, and surface roughness (Ra) analysis it has been ascertained that in modified ECM, tool material has little effect on MRR, and DR but other surface characteristics are influenced momentously. Overall, the Ti alloy as a tool has shown better performance than Al alloy with modified ECM and resulted in a 24.6% improvement in Ra and 64.24% in porosity (while machining Ti alloys), and 46.3% improvement in Ra and 79.70% in porosity (while machining Al alloys).