Analysis of abrasive flow machining with an electrochemical process aid

Electrochemical aided abrasive flow machining (ECAFM) is possible using polymeric electrolytes. The ion conductivity of electrolytes is many times lower than the conductivity of electrolytes employed in ordinary electrochemical machining (ECM). Additions of inorganic fillers to electrolytes in the form of abrasives decrease conductivity even more. These considerations explain why the interelectrode gap through which the polymeric electrolyte is forced should be small. This in turn results in greater flow resistance of polymeric electrolyte, which takes the form of a semi-liquid paste. Rheological properties are also important for performance considerations. Experimental investigations have been carried out for smoothing flat surfaces and process productivity in which polymer electrolytes as gelated polymers and water-gels based on acryloamide were used.