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In pulse electrochemical machining (ECM), it has been found that the low-level voltage of the applied pulse influences the tool electrode wear and the machining accuracy. In order to acquire a higher machining accuracy, the relationship between the low-level voltage and the machining characteristics was experimentally investigated. It was found that a raised low-level voltage not only prevents the tool electrode wear, but also improves the machining speed. Furthermore, it was found that there exits an optimal low-level voltage for improving the machining accuracy. In order to investigate the cause of this phenomenon, the electrolyte in the gap area was modelled and simulated using FEM software. It was found that bubbles generated by applying low-level voltage improve the machining characteristics. : Pulse ECM, Machining accuracy, Tool wear, Machining speed, FEM, Analysis

Study on Optimal Pulse Waveform for Machining Characteristics in Wire ECM