348

R. A. Mahdavinejad and M. R. Hatami

& where, ra , A, Z a and F are atomic mass, atomic number, the density of anode and Faraday's constant respectively. As the electrodes are cylindrical, in order to solve the equations the cylindrical coordinate system is used. The machining is done in radial direction and the normal gap is defined as:

d = r - r0

(5)

where r and r0 are the radius of the points on the inner surface of the chamber and the radius of the tool respectively. In order to determine the current density on the surface of the workpiece a linear approximation of the electrical potential distribution can be used along the machining gap, so that:

UE d The following equation can be used to determine the variations of r [1]: iA = Ke

(6)

D
2 2

r UE = KeKv grad r t r r0

(7)

r U E r 1 r r = KeK v + + t r r0 r r Z

SI
2

where Kv is the electrochemical machinablity coefficient. In cylindrical coordinate this equation can be written as follows: (8)

In this polishing condition, the tool electrode is fixed into the pipe without any movement. Besides, the machining rate is constant in all radial directions. Therefore, this equation can be simplified as follows:
dr UE = Ke Kv dt r r0

of
t
0

(9)

The solution of this equation is:

ive
r r1 0
r
1

(r r0 )dr = K e K v (U E) dt
e

(r r ) dr = K

Kv (U E)dt
t
0

ch Ar

1 2 r r0 r = K e . K v (U E) t 2 r
2

r 2 2r0 r + (2r0 r1 r1 2K e K v (U E) t) = 0
2 2

r = r0 r0 (2r0 r1 r1 2K e K v (U E) t) r = r0 + r0 2 (2r0 r1 r1 2 2K e K v (U E) t)

(10)

Since r>r0 then:

(11)

Let C = K e K v (U E) , where C is m2s-1, the machining constant for the set of workpiece and electrolyte, then
r = r0 + r0 2 (2r0 r1 r1 2 2C t)

(12)

Using this equation the radius of the rifle at the bottom (r) is determined and then the machining depth can be calculated. According to the Eqs. (5) and (12), to determine the depth of the rifle two conditions can be considered; 1) The feed speed of the tool is variable. 2) The feed speed of the tool is constant. In the latter case the electrical voltage is variable, but the machining time is constant. In the former case the electrical voltage of the system is 10 V, therefore, the feed speed of the tool is as follows:
Iranian Journal of Science & Technology, Volume 32, Number B4 August 2008

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