Meichsner, GunnarGunnarMeichsnerPetzold, TomTomPetzoldHackert-Oschätzchen, MatthiasMatthiasHackert-OschätzchenEdelmann, JanJanEdelmannSchubert, AndreasAndreasSchubertPutz, MatthiasMatthiasPutzHahn, GeorgGeorgHahn2022-03-132022-03-132017https://publica.fraunhofer.de/handle/publica/398829In the field of spare parts production with small quantities and low stockholding one main method is reduplication of precise internal geometries from a defect part to a spare part. One conventional manufacturing technology for this reduplication is broaching. Since broaching requires extensive and expensive tools especially for small quantities a more resource efficient technology is aspired. Electrochemical machining (ECM) is a potential technology which meets these requirements. ECM transfers a cathode geometry to a workpiece based on anodic dissolution [1]. For this purpose, a specific design for the cathode as well as for the process is required [2]. In the context of process design multiphysics simulation allows a time- and cost-efficient determination of proper process parameters and enables conclusions for the optimization of the cathode geometry [3]. The paper shows an experimental study on the reduplication of precise internal geometries using pulsed electrochemical machining (PECM) applying a two-step approach. Therefore in a first step an initializing workpiece was used to generate a cathode with PECM. This initializing workpiece consists of an internal bore with a diameter of 32 mm. In the second step the reduplication of this internal bore into a workpiece by PECM applying the generated cathode was performed. The workpiece was made of a hardened powder metallurgy steel SAM 10. In the experiments the voltage was varied in a range from 10 V to 17 V and the feed rate was varied from 0,5 mm/s to 1,1 mm/s. By help of the experimental study the influence of both PECM processes on the reduplication result can be determined.enPECMelectrochemical machininginternal geometriesconference paper