Thermographic in-situ investigation of precise electrochemical machining

Modelling of ECM is a powerful tool to improve the cost- and time intensive tool-development process. While different simulation models for DC-ECM have been published and validated, the virtual prediction of the process variant with oscillating cathode is still hindered by its highly transient nature. In order to develop and later validate a model of PECM, high-resolution information on the temperature profile and gas evolution during one oscillation is required. Temperature and gas concentration both increase during the electric pulses and constantly decrease due to flushing. This paper presents a fixture that allows the thermographic analyses of the PECM process. Consequently, the conditions within the electrolyte channel during PECM are captured which allows a deeper understanding of the process.