ECM Production Made Practical by Good Tooling and Controls 640528
This paper discusses control and tool design requirements to make ECM, or electrochemical machining, a practical production operation. Dimensional control of parts is obtained by close mating of tool geometry to the work. Control tolerance and repeatability are obtained by control of the tool-work gap. Gap equations for static and uniform tool speed machining are presented. Solution conductivity is the most important consideration for ECM control. Hydrogen evolution is the major factor influencing conductivity and can be controlled by high flow and pressure. Temperature control and 100% filtration are required for close work. Typical data and general calculations are given to establish control limits.