The Preliminary Study Of On-line Measuring The Gap In Electrochemical Machining Based On Analysis Of Mechanical Test

The gap of Electrochemical Machining (ECM) is a crucial factor in ECM .The state of machining gap influences the shape precision and surface quality of ECM directly. As the gap is very small (normally 0.1~1mm),and also the gap is affected by lots of complex process factors ,it makes testing and controlling the gap becomes the most outstanding difficulty in the application of ECM. Untill today, there is no effective way to on-line-measuring the gap. On the base of the comparison of the exiting test and controll methods, a kind of project of on-line-measuring the gap in ECM based on the analysis of mechanical test is pointed out. That is building the mathematics relationship between the forces acting on the electrode and the gap , then through on-line-measuring the forces to test the gap. In this paper ,the design of a suit of ECM clamp and a six-aix-forces sensor is introduced. A verifying experiment project is confirmed.,then the experiment on the flat electrode is done, the mathematics equation between the forces acting on the electrode and the gap is set out. At last, the conclusion is fully analyzed and discussed, some improvements are given out and the prospect of later research is put forward.