Research on eco-friendly electrochemical micro-machining by using ultra-low concentration electrolyte

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Although difficult-to-cut metallic materials can be machined by electrochemical machining (ECM), the impact to the environment and lower machining rate are bottlenecks to enhance its application. In this research, an ECM method using a very low concentration electrolyte was proposed to realize a precision machining at a high speed for difficult-to-cut materials, and thus to minimize the adverse effects to the environment. In order to achieve the goal, the influence of electrolyte concentration on machining characteristics was investigated experimentally and theoretically with the equivalent circuit. Besides, the fabrication of WC micro shafts with high speed and WC machining with ultrasonic vibration and bipolar pulses were realized. In addition, the detection and control system of the machining state and gap distance, and the method to decrease the electrode wear were proposed. As a result, a machining system suitable for ECM using low concentration electrolyte was constructed.