Influence of Currents Density and Gap Size on Metal Removal Rate and Surface Roughness in Electrochemical Machining (ECM)

Abstract

Electrochemical machining one of non traditional method which is used tomachine a complex shape such as that uses the chemical reaction associated withelectric current to remove metals. In this study the ECM was used to remove themetals from the internal hole of the workpiece (medium carbon steel) by immersing itin electrolyte (250g of NaCl for every litter of H2O) with tool is made of brass.The,m research focuses on the effect of the change in gap dimensions and thecurrents density on the metal removal rate (MRR) and surface roughness of theworkpiece the results obtained show that increasing of gap size between the tool andthe workpiece from (1 to 3mm) leads to increase the surface roughness (46%) andwhile the material removal rate (MRR) decreases (16%) at a current density (2.856Amp/cm2). Also increasing of the current density from (2.4485 to 3.6728 Amp/cm2),the surface roughness of the workpiece decreases (31%) while the Material RemovalRate (MRR) increases (93.9%) at a gap size of (1mm).