Optimization of Key Process Parameters on Electro Chemical Honing (ECH) of External Cylindrical Surfaces of Titanium alloy Ti 6Al 4V

Abstract

Electrochemical honing (ECH) is one of the most advanced precision machining process used for finishing of cylinders and gears, based on the combination of electrochemical machining process having high material removal rate and generation of controlled smooth surface finish by conventional honing process. ECH is a well known process for offering an excellent work surface quality on material of any hardness as long as it is electrically conductive. The process made ECH as an ideal choice for improving the surface quality of critical components made of hard and tough materials like Inconel, Incolay, Titanium & Nickel alloys etc. It also describes the design and fabrication of an indigenously developed tooling setup for ECH of an external cylindrical components. Titanium alloy (Ti 6Al 4V) and EN8 Steels are used as work piece material for carrying out the experimentations. Various key process parameters are discussed for better surface finish Ra and for more material removal and their effect on ECH process is discussed for Ti alloy. It compares and evaluates the percentage improvements in surface roughness values, with respect to processing time (PT) and distinguishes the surface characteristics of micro and macro level. Electro chemical honing process has been employed to achieve highest material removal rate with the best surface qualities. © 2017 Elsevier Ltd.