FURTHER PROBLEMS AFFECTING THE PRODUCTION OF ELLIPTICAL HOLES BY ECM

RCM has found wide applications in aerospace industries. However, tool design in ECM is still a problem which delays the use of this process. This paper has fccused attention on some of the problems that are to be studied before it would be possible to obtain an analytical design of toolings for ECM. Furthermore, this. paper has emphasized that each component in ECM presents its own particular problems and each must be treated on its own merits as has been shown through producing the elliptical hole shape. Inequality of electrolyte distribution, different electrolyte path lengths and variations in current density have been found to be the main features that characterize the nature of the elliptical hole shape by ECM. Resistance model technique has been suggested and modified to use for analysis of the elliptical hole shape. A parametric study of the process which highlights certain guidelines for ECM tooling designer is also presented. Experimental results have revealed significant variations in the resultant side gap length at major and miner diameterS of the tool. The experimental tests have been in agreement with the present analysis. Further, resistance model technique has proved its validity for use in evaluating the power consumption in ECM.