Investigation of working gap phenomena in Mechano-Electrochemical Milling

Abstract The Mechano-Electrochemical Milling (MECM) process combines Electrochemical Machining (ECM) with a mechanical cutting process. The exploitation of the strengths of both proven technologies offers opportunities for more efficient machining of both existing and new hard-to-cut materials. Notwithstanding research has been done on the material removal rate and material removal mechanisms of this new process, the mutual influences of the two material removal components on the electrolyte behaviour in the working gap are still unclear and are subject of investigation in this paper. Phenomena such as bubble formation, a more irregular flow and a more complex surface topography during machining have a direct influence on the combined material removal mechanism and the resulting machined surface. Investigation of these phenomena is done through online high-speed observation of the electrolyte behaviour in the working gap during MECM under a series of different parameter conditions. These observations, together with other online and offline measurements such as current-voltage and infrared imaging, allow to better explain the process behaviour.