Modeling and Simulation of the Shape Error in the ECM Process

Rajurkar, K. P.; Liu, W. H.; Wei, B.; Hewidy, M. S.; Kozak, J.

doi:10.21608/erjm.1998.73035

Modeling and Simulation of the Shape Error in the ECM Process

Document Type : Original Article

Authors

¹ Nontraditional Manufacturing Research Center Industrial and Management Systems Engineering Department University of Nebraska-Lincoln, Lincoln, NE 68 5 88

² Visiting from Menoufia University, Egypt

³ Visiting from Warsaw university of Technologyz Poland

10.21608/erjm.1998.73035

Abstract

Accuracy in ECM is still a problem that restricts the application of
this technology for accurate applications. The present investigation submits a
theoretical and experimental study about shape error in the ECM process which
has not been attempted before. Feed rate, applied voltage, electrolyte
conductivity and initial gap size have been considered the main factors affecting
the shape error value (sometimes reached 40 p1 for a 40 mm workpiece
length). Experimental results have been found to agree with the estimated values
with a difference less than 0.01 mm. The present results emphasize the
importance of the consideration of the shape error factor for accurate tool
design and shape prediction