On some aspects of surface formation in ECM

The mechanism of surface formation in electrochemical machining (ECM) is notfully understood because of the complex heterogenous reactions possible in theinter-electrode gap. A complete understanding of the flow phenomenon can provideconsiderable information in this regard. Qualitative and quantitative analyses ofsurface profiles presented in this paper highlight the significant effect of the flowvelocity on surface formation. The flow velocity significantly affects the shortwavelength irregularities of the surfaces produced in anodic smoothing. At lowervelocities, the workpiece grain size also influences the surface finish. The smallergrains yield better finish when the Reynolds number is below 10,000. The cathodereproduction is poor with increasing velocity but the overall finish is found to begood. Short wavelength irregularities present in the reproduced profiles retluceconsiderably with increasing flow velocity. Belter reproduction is seen when the layof the lool is across the flow. Such studies are significant in understanding theanodic smoothing and cathode reproduction, and these experimental resultsaugment the theoretical models developed in this field. © 1981 ASME.