Electrochemical machining in-process data collection and control

Electrochemical machining (ECM) is a fast and efficient method to fabricate intricate metal parts. However, tooling is often expensive; and electical power consumption is relatively high. The precision of an ECM process is dependent upon several variables which often cannot be predicted in the initial tool design. This leads to iterative tool adjustments until the desired level of precision is achieved. A system was devised to use a computer for collecting data from the ECM process and for monitoring and controlling ECM operations. It is believed that these data collections and analyses will lead to the formulation of algorithms to produce parts with better tolerances and will allow more efficient uses of the ECM machines. One algorithm has been developed to allow the efficient ECM of large-surface-area parts. Such programs and equipment will enhance the competitive position of the ECM process in machining applications previously performed by more conventional methods while minimizing electrical power consumption