Inner surface grooving of cylindrical parts in Electrochemical Machining

The use of difficult-to-machine metals such as Ti6Al4V, Inconel 718 and Stellite21 is recently increasing in the leading production industries of the country such as aerospace, medical and defense. The production of such materials using conventional manufacturing methods causes damage to the tool surface and deterioration in the mechanical properties of the workpiece. Electrochemical machining (ECM), which is a non-contact machining method, is preferred for processing such materials due to its high surface quality and low tooling costs. The subject of this thesis presented is; it is about investigating the applicability of the grooving process to hollow cylindrical parts with ECM, which is important in various industries. This method is already known to be used for processing freeform surfaces. However, there is no knowledge about performing the grooving process on the inner wall in cylindrical parts. Therefore, in the preliminary study, when VBN surfaces were compared with TEIN surfaces for 1 and 1.5 mm gap distances at 20 V, it was determined that the MİH value increased by 17.65% and 20.01%, respectively. For this, experiments were carried out with different ECM process parameters and variable parameter values and the results were compared. In this context, in order to open a groove on the cylindrical part, the apparatus whose details are given in this thesis has been designed, and the cylindrical workpiece has been machined with the ECM method with the help of a tool that is fixed in the workpiece or displacement along the axis by entering the workpiece according to the movement of the tool whose details will be given. In particular, there is an increase in the material machining speed of approximately 19% compared to the tool feed rate and rapid exit movement type determined in the moving tool type, which is the same test condition. This ratio was calculated as approximately 22% in the same duty cycle compared to the fixed tool.