Design and automation of robotic electrochemical machining bench

Hard to cut materials such as titanium, inconel and nickel-based superalloys are used in the medical, automobile, defense, aircraft and aerospace industries. These materials are difficult to machine using traditional machining methods. In electrochemical machining; due to the uncertainty of the material removal rate and problems in mathematical modeling, a robotic electrochemical machining bench is manufactured. Robotic electrochemical machining bench is controlled parameters such as voltage, current, flow, workpiece and tool positions and temperature. 36 experiments are carried out using the parameters of feed rate, electrolyte flow rate and number of cycle. The highest amount of material removal rate (60 mg); the highest flow rate (4.38 lt/min) and the number of cycle (11 cycle) are reached. The highest feed rate (20 mm/sec), the lowest material removal rate amount is reached. As the feed rate increases, the machining time decreases, thus resulting in a decrease in the amount of material removal rate.