A Comparative Analysis of the Two Electrolyte Flow Configurations in Electrode Tool to Improve Efficiency in Electrochemical Machining

Abstract Electrochemical machining (ECM) is defined as a non-conventional method of manufacturing that is greatly employed in processing of materials with complex geometry which are hard to be machined, providing high accuracy and excellent surface finish. ECM is influenced to higher extent by the configuration of the electrolyte flow and design of electrode tooling. In this work, two types of electrolyte flow configurations in electrode tooling are studied and compared: straight flow and side nozzle flushing flow. The effects of these configurations on material removal rate (MRR) and surface roughness were investigated both experimentally and numerically. The results emphasize the significance of the choice of electrolyte flow configuration in improving the uniformity of ion transport, flow turbulence during machining and quick heat dissipation. According to the findings, it is clear that the hollow electrode with straight flow has the best material removal rate with a percentage increase of 4.61 percent recording a rate of 0.4352 g/min, as compared to the rigid electrode with nozzle flushing flow which records 0.416 g/min. Also, the hollow electrode at straight flow showed the least extreme surface roughness, a percentage decrease of 28.52% with the least extreme of 2.030 μm and the robust electrode surface with the nozzle flow of 2.840 μm. These findings have fundamental implications for the improvement of ECM technologies with regards to productivity, energy consumption, and accuracy of machining processes. In regards to the finding, the research provides an insight into the impact customization of flow and tooling with regards to the processes in the electrochemical operation.