Short-circuit avoidance in electrochemical machining based on polarization voltage during pulse off time

  • Wei Chen
  • Fuzhu HanEmail author


Electrochemical machining (ECM) is an important processing method in aerospace manufacturing and has been used in many applications. The short circuit between the tool electrode and the workpiece during processing is the main factor affecting process stability, machining efficiency, and the workpiece surface quality. Most short-circuit detection methods identify a large current after the occurrence of a short circuit, by which time burns and other damage caused by a short circuit have already occurred. This study found that there is a polarization voltage that does not corrode the workpiece in pulse ECM (PECM), and the voltage varies with the characteristics of the electrolyte. By measuring the polarization voltage during the pulse off time, this paper presents a new method to enable ECM gap detection and machine tool feed servo feedback control. The method can prevent short-circuit burns and improve the stability and efficiency of ECM.


Electrochemical machining Pulse power supply Gap detection Short-circuit avoidance 


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Funding information

This work was supported by the National Key R&D Program of China (grant number 2018YFB1105900), the National Natural Science Foundation of China (grant number 51575308), and Suzhou-Tsinghua Foundation (grant number 2016SZ0307).


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Copyright information

© Springer-Verlag London Ltd., part of Springer Nature 2019

Authors and Affiliations

  1. 1.Department of Mechanical EngineeringTsinghua UniversityBeijingChina
  2. 2.Beijing Key Lab of Precision/Ultra-precision Manufacturing Equipments and ControlTsinghua UniversityBeijingChina

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