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 to machine a complex shape such as that uses the chemical reaction associated with electric current to remove metals. In this study the ECM was used to remove the metals from the internal hole of the workpiece (medium carbon steel) by immersing it in electrolyte (250g of NaCl for every litter of H 2 O) with tool is made of brass. The,m research focuses on the effect of the change in gap dimensions and the currents density on the metal removal rate (MRR) and surface roughness of the workpiece the results obtained show that increasing of gap size between the tool and the workpiece from (1 to 3mm) leads to increase the surface roughness (46%) and while the material removal rate (MRR) decreases (16%) at a current density (2.856 Amp/cm 2). Also increasing of the current density from (2.4485 to 3.6728 Amp/cm 2), the surface roughness of the workpiece decreases (31%) while the Material Removal Rate (MRR) increases (93.9%) at a gap size of (1mm). ‫واﻟﺧﺷوﻧﺔ‬ ‫اﻟﻣﻌدن‬ ‫ازاﻟﺔ‬ ‫ﻛﻣﯾﺔ‬ ‫ﻋﻠﻰ‬ ‫اﻟﻔﺟوة‬ ‫وﺣﺟم‬ ‫اﻟﺗﯾﺎر‬ ‫ﻛﺛﺎﻓﺔ‬ ‫ﺗﺄﺛﯾر‬ ‫اﻟﻛﮭروﻛﯾﻣﯾﺎﺋﻲ‬ ‫اﻟﺗﺷﻐﯾل‬ ‫ﻋﻣﻠﯾﺔ‬ ‫ﻓﻲ‬ ‫اﻟﺳطﺣﯾﺔ‬ ‫اﻟﺧﻼﺻﺔ‬ ‫اﻧواع‬ ‫ﻣن‬ ‫ﻧوع‬ ‫ھو‬ ‫اﻟﻛﮭروﻛﯾﻣﯾﺎﺋﻲ‬ ‫اﻟﺗﺷﻐﯾل‬ ‫دة‬ ‫اﻟﻣﻌﻘ‬ ‫ﻛﺎل‬ ‫اﻻﺷ‬ ‫ﻐﯾل‬ ‫ﻟﺗﺷ‬ ‫ﯾﺳﺗﺧدم‬ ‫اﻟذي‬ ‫اﻟﻼﺗﻘﻠﯾدي‬ ‫اﻟﻘطﻊ‬ ‫اﻟﻛ‬ ‫ﺎر‬ ‫اﻟﺗﯾ‬ ‫ﻊ‬ ‫ﻣ‬ ‫ﺎﺋﻲ‬ ‫اﻟﻛﯾﻣﯾ‬ ‫ل‬ ‫اﻟﺗﻔﺎﻋ‬ ‫ﺗﺧدم‬ ‫ﺗﺳ‬ ‫ﻲ‬ ‫واﻟﺗ‬ ‫دن‬ ‫اﻟﻣﻌ‬ ‫ﺔ‬ ‫ﻻزاﻟ‬ ‫ﺎﺋﻲ‬ ‫ﮭرﺑ‬. ‫ﺗﺧدام‬ ‫اﺳ‬ ‫م‬ ‫ﺗ‬ ‫ث‬ ‫اﻟﺑﺣ‬ ‫ذا‬ ‫ھ‬ ‫ﻲ‬ ‫ﻓ‬ (ECM) ‫اﻟﻣﺷﻐﻠﺔ‬ ‫ﻟﻠﻘطﻌﺔ‬ ‫اﻟداﺧﻠﻲ‬ ‫اﻟﺛﻘب‬ ‫ﻣن‬ ‫اﻟﻣﻌدن‬ ‫ﻻزاﻟﺔ‬) ‫ﺎرﺑون‬ ‫اﻟﻛ‬ ‫ﻣﺗوﺳط‬ ‫ﻓوﻻذ‬ ‫ﻧوع‬ (‫ﻼل‬ ‫ﺧ‬ ‫ن‬ ‫ﻣ‬ ‫اﻟﻛﺗروﻟﯾﺗﻲ‬ ‫ﺑﻣﺣﻠول‬ ‫ﻏﻣرھﺎ‬) 250 ‫ﻣن‬ ‫ﻏم‬ NaCl ‫ﻣن‬ ‫ﻟﺗر‬ ‫ﻟﻛل‬ H 2 O (‫و‬ ‫اﻟﺑراص‬ ‫ﻣن‬ ‫اداة‬ ‫أﺳﺗﺧدام‬. ‫ﺑ‬ ‫ر‬ ‫اﻟﺗﻐﯾ‬ ‫ﺄﺛﯾر‬ ‫ﺗ‬ ‫ﺔ‬ ‫دراﺳ‬ ‫ﻰ‬ ‫ﻋﻠ‬ ‫ث‬ ‫اﻟﺑﺣ‬ ‫ز‬ ‫رﻛ‬ ‫دن‬ ‫اﻟﻣﻌ‬ ‫ﺔ‬ ‫ازاﻟ‬ ‫ﺔ‬ ‫ﻛﻣﯾ‬ ‫ﻰ‬ ‫ﻋﻠ‬ ‫ﺎر‬ ‫اﻟﺗﯾ‬ ‫ﺔ‬ ‫ﻛﺛﺎﻓ‬ ‫ﯾم‬ ‫وﻗ‬ ‫وة‬ ‫اﻟﻔﺟ‬ ‫ﺎد‬ ‫ﺄﺑﻌ‬ ‫ﺎﺋﺞ‬ ‫اﻟﻧﺗ‬ ‫رت‬ ‫ﮭ‬ ‫واظ‬ ‫ﻐﻠﺔ‬ ‫اﻟﻣﺷ‬ ‫ﺔ‬ ‫ﻟﻠﻘطﻌ‬ ‫طﺣﯾﺔ‬ ‫اﻟﺳ‬ ‫وﻧﺔ‬ ‫واﻟﺧﺷ‬ ‫ﺔ‬ ‫واﻟﻘطﻌ‬ ‫اﻻداة‬ ‫ﺎﺑﯾن‬ ‫ﻣ‬ ‫وة‬ ‫اﻟﻔﺟ‬ ‫م‬ ‫ﺣﺟ‬ ‫ﺎدة‬ ‫زﯾ‬ ‫د‬ ‫ﻋﻧ‬ ‫ﻗﯾم‬ ‫ﻋﻧد‬ ‫اﻟﻣﺷﻐﻠﺔ‬) ‫ﻣن‬ 1 ‫اﻟﻰ‬ ‫ﻣم‬ 3 ‫ﻣم‬ (‫طﺣﯾﺔ‬ ‫اﻟﺳ‬ ‫وﻧﺔ‬ ‫اﻟﺧﺷ‬ ‫ﺎدة‬ ‫زﯾ‬ ‫ﻰ‬ ‫اﻟ‬ ‫ﺗؤدي‬) 46 (% ‫ﺔ‬ ‫ازاﻟ‬ ‫ﺔ‬ ‫ﻛﻣﯾ‬ ‫ﺎ‬ ‫ﺑﯾﻧﻣ‬ ‫ﺑﻧﺳﺑﺔ‬ ‫ﺗﻘل‬ ‫اﻟﻣﻌدن‬) 16 (% ‫ﻧ‬ ‫ﻋ‬ ‫ﺗﯾﺎر‬ ‫ﻛﺛﺎﻓﺔ‬ ‫اﺳﺗﺧدام‬ ‫د‬) 2.856 ‫اﻣﺑﯾر‬ / ‫ﺳم‬ 2 (. PDF created with pdfFactory Pro trial version www.pdffactory.com