Experimental Studies on the Effect of Electrolyte Jet Patterns Over Metal Removal Rate in ECM Process

Electrochemical Machining (ECM), over the past decades has become one of the important methods in metal removal processes. ECM has established itself as one of the major alternatives to conventional methods for machining hard materials and complex contours without the residual stresses and tool wear. Studies on Metal removal rate (MRR) are of utmost importance in ECM, since it is one of the determining factors in the process decisions. In this work, an experimental investigation has been made on various process parameters involved in the Metal Removal Rate using ECM on AISI 1035 steel with NaCl aqua solution for three different electrolyte jet patterns. The effect of electrolyte jet patterns over MRR has been studied in detail and results evolved. Experimental metal removal rate has been calculated for different jet configurations and the obtained results reveal that the electrochemical machining of AISI 1035 by circular straight jet pattern gives better MRR than the other jet patterns.