The computer aided simulation of electrochemical process with universal spherical electrodes when machining sculptured surfaces

In this paper a mathematical model, the results of computer simulation and experimental investigations of electrochemical machining with a spherical tool-electrode are presented. The experimental investigations were carried out in order to evaluate the influence of working voltage, velocity of electrode displacement, initial interelectrode gap size, tool-electrode cross feed and electrode radius on removed material excess thickness, machined surface height of waviness, surface roughness and metal removal rate. Accuracy of computer simulation evaluated by differences between results of experimental tests and computer simulation depends on accuracy of a priori estimation of electrochemical machining coefficient, total overpotential of electrode processes, electrical conductivity of electrolyte, etc. The results of application of neural network to prediction of height of surface waviness and thickness of removed allowance which depend on setting parameters of electrochemical machining (ECM) are also presented. The developed software for simulation of the ECM process with universal spherical tool-electrode and trained neural networks are useful for process analysis, machined surface prediction and optimisation. (C) 2000 Elsevier Science B.V. All rights reserved.