Mathematical modeling for controlled electrochemical deburring (ECD)

Abstract Deburring is the finishing technique required for manufacturing of precise components. In industry manual methods are commonly employed for burr removal. Deburring operation with high efficiency and full automation is a very difficult task. Further, removal of internal burrs of various size and shape sometimes becomes extremely difficult task. In such situation electrochemical deburring (ECD) offers a potential solution to such problem. In case of ECD, burr is removed by electrochemical dissolution, rather than by mechanical force. Due to non-contact nature of the process there is no residual stress and thermal effect on the job surface. For successful utilization of ECD, in present day manufacturing, still demands for more intensive research, including the parametric analysis of the process. In the present paper the characteristics of ECD is analyzed through a developed mathematical model and main influencing factors such as time, initial burr height, inter-electrode gap, voltage and base material removal have been examined. The present study proves that predictions based on the developed mathematical model are in very good agreement with the experimental results. The paper also highlights the scheme of the developed ECD system designed to operate within the parametric limits. The present paper through various parametric studies will act as a guideline for the operation of an ECD system.