Design of continuity processes of electrochemical finishing and grinding following turning

A newly designed finishing process utilizing an effective electrode and a grinding tool to execute the continuous electrochemical finishing and grinding processes following turning is described in this paper. The proposed process can be used for a variety of turning operations. Electrochemical finishing and grinding can be performed following the finishing process on the same machine by using a simple attachment. The factors affecting electrochemical finishing, grinding performance, and electrochemical finishing are discussed. The electrode was tested with both continuous and pulsed direct current. A higher work piece rotational speed produced a better finish. Changing the electrode design from a semicircle to a wedge form with a small end radius caused the electrolytic products and heat to dissipate more rapidly and provided the best finishing. Pulsed direct current finishing was slightly better than using continuous direct current finishing. However, the use of pulsed current would increase machining time and cost. This paper was recommended for publication in revised form by Associate Editor Dae-Eun Kim Dr. P.S. Pa obtained his doctorate at National Tsing Hua University, Taiwan. Presently he is an Associate Professor at Graduate School of Toy and Game Design of National Taipei University of Education. His fields of interest are innovative design and manufacturing processes. His current research includes ECM process for mould and die materials, precision finishing, toy design, and electro-optical engineering.