Brief Paper: Electric Pulse Assisted Milling

Abstract Electrically assisted machining involves the application of an electric current through the workpiece-tool interface to enhance machining performance. Literature suggests that applying electric current during machining can reduce machining forces, improve surface finish, and increase efficiency, potentially making the process more effective and economical. These positive effects are often attributed to the electro-plastic effect, where the electric current allegedly induces plasticity in the material and describes the non-thermal effect of the electric current. In the present work, electrically assisted milling was performed with the application of pulsed electric current while the cutting tool engaged with the material. Important parameters such as current amplitude and machining forces were recorded to investigate the effect of electrical and mechanical factors during the process. Additionally, numerical simulations were conducted to estimate the current density distribution and the temperature profile within the workpiece. The findings contradict previous literature assumptions, revealing that the electroplastic effect may not be responsible for the observed improvements. Instead, it appears that any reductions in force or enhancements in surface quality are more likely due to localized heating in the tool rather than changes in the material properties of the workpiece itself. This insight suggests a shift in understanding electrically assisted machining mechanisms, emphasizing the role of thermal effects at the tool rather than electro plastic changes in the workpiece.