Question

An electrochemical machining (ECM) is to be used to cut a through hole into a 12 mm thick aluminum plate. The hole has a rectangular cross-section, 10 mm × 30 mm. The ECM operation will be accomplished in 2 minutes, with efficiency of 90%. Assuming specific removal rate for aluminum as 3.44 × 10-2 mm3 /(A s), the current (in A) required is __________ (correct to two decimal places).


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Answer :

968.99

Volume of metal to be removed = (10*30)*12 mm3 = 3600 mm3

Ideal energy required = 3600mm3 A*s/ 3.44*10-2mm3 = 104651.163 As

Actual energy required = 104651.163 As/ 0.9

                                              = 116279.07 As

                    Time is 2 min = 120 s

                              Current = 116279.07 A/120 = 968.992A

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