Manufacturing of axial slots by electrochemical machining process

Document Type : Original Article

Authors

Faculty of Engineering, Menoufia University Shebin El-Kom, Egypt.

Abstract

Axial slots are usually required for generator rotors, journal bearing and sliding bearing.
Machining and finishing of these slots usually achieved through milling techniques. However, it
has been found that there is difficulty in achieving adequate surface finish and acceptable
dimensional accuracy of the resultant slot shape. Recently, electrochemical machining (ECM) has
been suggested as a promising technique valid to produce these slots under high surface quality
and min. machining costs. The previous attempts have been carried out through successive ECM
processes, first to machine the hole, and then to create the slots. In the present work, an attempt
has been submitted to get both of the hole and slots in one pass as a final process. A special ECM
test rig has been designed for this aim. The main affecting parameters on the resultant slot shape
were, tool geometry, applied voltage and feed rate. The results obtained in this work enable the
manufacturing engineer to select the required shape dimensions through different combinations
of FCM parameters.