System Design and Experiments of Tool Setting Detection in Micro-Electrochemical Machining Based on LabVIEW

The initial gap in electrochemical machining (ECM) is a significant affection parameter for ECM process and machining stability. A tool setting detection system based on LabVIEW technology has been designed to realize the rapid and accurate pinpoint between two electrodes since the initial gap of micro-ECM is usually only a few microns to tens of microns. The system can not only efficiently complete tool setting detection in micro-ECM, but also real-time monitor the change of processing current. 120 comparative experiments have been conducted to evaluate the erosion amount of workpiece material, the reliability, repeatability and positioning accuracy of micro-ECM process in the conditions of wet tool setting compared with dry tool setting. The experimental results have shown that adopting the tool setting detection system designed in this paper, the erosion rates of cathode and anode after 120 repeated wet tool setting experiments were only 0.21% and 0.02%, the positioning accuracy and repeatability can completely meet the requirements of tool setting in micro-ECM, and greatly improve the efficiency of the micro-ECM.