Mathematical theory of electrochemical machining 2. Anodic shaping

Further solutions to the potential equation with moving boundary conditions, applicable to the electrochemical machining process, are presented. A theory is proposed for the machining of an arbitrary distribution of irregularities on to an anode for the cases where the cathode profile is specified and the resultant anode shape must be found, and where a cathode profile must be designed to give a required anode shape. Limitations on the application of this theory are discussed. The effects of overpotential are also discussed; overpotential only at the cathode is shown to reduce the limiting amplitude which can be obtained on the anode, and to increase the machining time required to achieve it. Overpotential only at the anode has no effect on this limiting amplitude, but again increases the necessary machining time

Design and characterisation of ultrasonic cutting tools

Cutting of food products and other materials with ultrasonically assisted tools has demonstrated significant benefits including reduced wastage and improved cut quality. However, the success of the technology relies on careful design of the ultrasonically excited tools and transmission components. In this paper, the different challenges of tool design are discussed with reference to two cutting devices. The studies demonstrate that accurate characterisation of the vibration behaviour of the tool and an understanding of the effects and limitations on vibration responses of design modifications, allows tool performance to be enhanced in the design