Paper Titles
Increasing Strength of Recycled Materials by Fiberglass Pulverization and Powder Direct Molding
p.29
Evaluation of Anti-Fouling Behavior of Silver Nanocomposites Made by Nano-Coating Fragmentation
p.37
Shape Memory Behavior of 3D-Printed Biomedical Polyurethane with Room Temperature Transition
p.45
Analysis of Connection Geometries for Segmented Stator Cores Machined with Laser Beam Cutting
p.55
Estimation of the Lateral Gap in PECM: A Case Study on Tool Steel S390
p.63
Beading as a Stabilising Element for Thin Wooden Panels
p.75
Influence of Variable Radius Die Geometry on Tube Bending: A Finite Element Parametric Study
p.87
Design and Manufacturing of Complex Geometry PEEK Component through Fused Filament Fabrication
p.99
Development of an Initial FEM Framework to Model Particle-Substrate Contact in Fluidized Bed Finishing of L-PBF Parts
p.113

Estimation of the Lateral Gap in PECM: A Case Study on Tool Steel S390

Article Preview
View Pdf By email

Abstract:

Pulsed Electrochemical Machining (PECM) is an established process that is characterized by the machinability of metallic workpieces regardless of their mechanical properties. Applications of PECM, such as the manufacturing of punches made from hardened tool steel, often utilize the lateral working gap for the final shaping of the workpiece. A major challenge in designing an economically viable removal process is the prediction of the lateral gap for certain targeted feed rates. This case study presents a design strategy for the design of PECM applications utilizing the lateral gap. Based on a characterization of the material removal characteristics of the hardened tool steel S390, preliminary experiments were conducted to characterize the relation between (1) the feed rate, the current density in the frontal gap and the voltage and (2) the lateral gap. Further, multiple parameter sets were derived for the machining with a targeted lateral gap. The validity of these parameter sets is verified experimentally. Based on these results, a cathode for the manufacturing of a demonstration punch was designed and manufactured. These demonstration punches were machined and the resulting dimensions evaluated. Lastly, fine adjustments regarding the process parameters were applied to achieve the targeted geometric accuracy.

You have full access to the following eBook
Special Materials and Processes Read eBook

Info:

Periodical:

Materials Science Forum (Volume 1187)

Pages:

63-73

DOI:

https://doi.org/10.4028/p-L9BoI3

Citation:

Cite this paper

Online since:

April 2026

Authors:

Richard Petermann*, Gunnar Meichsner, Pascal Clauß, Steven Nickel, Matthias Hackert-Oschätzchen

Keywords:

Lateral Gap, PECM, Pulsed Electrochemical Machining, S390, Working Gap

Export:

RIS, BibTeX

Permissions:

Creative Commons CC BY 4.0

Share:

Citation:

* - Corresponding Author

References

[1] F. Klocke, W. Koenig, Fertigungsverfahren Band 3. Springer Verlag, 2007.

DOI: 10.1007/978-3-540-48954-2

Google Scholar

[2] G. Meichsner, M. Hackert-Oschätzchen, M. Krönert, J. Edelmann, A. Schubert, M. Putz, Fast Determination of the Material Removal Characteristics in Pulsed Electrochemical Machining, Procedia CIRP 46 (2016) 123-126.

DOI: 10.1016/j.procir.2016.03.175

Google Scholar

[3] A. Schubert, G. Meichsner, M. Hackert-Oschätzchen, M. Zinecker, J. Edelmann, Pulsed electrochemical machining of powder metallurgy steels, 7th International Symposium on Electrochemical Machining Technology (2011), p.68–75.

DOI: 10.1016/j.procir.2016.03.175

Google Scholar

[4] R. Petermann, P. Clauß, P. Damm, G. Meichsner, M. Hackert-Oschätzchen, Experimental Derivation of Process Input Parameters for Electrochemical Precision Machining of a Power Metallurgical Tool Steel, Materials Research Proceedings 41 (2024).

DOI: 10.21741/9781644903131-260

Google Scholar

[5] F. Klocke, T. Herrig, M. Zeis, A. Klink, Experimental Research on the Electrochemical Machinability of selected γ-TiAl alloys for the manufacture of future Aero Engine Components, Procedia CIRP 35 (2015) 50-54.

DOI: 10.1016/j.procir.2015.08.050

Google Scholar

[6] A. Frank, T. Hall, M. Zeiner, D. Bähre, Study of Pulse Electrochemical Machining on Conventionally and Additively Manufactured Inconel 718 Workpieces, 20th International Symposium on Electrochemical Machining Technology (2024) 11-19.

Google Scholar

[7] R. Petermann, P. Clauß, G. Meichsner, F. Meyer, M. Hackert-Oschätzchen, Experimental characterisation of lateral machining gap during Pulsed Electrochemical Machining for corrosion resistant tool steel, Procedia CIRP 137 (2025) 306-311.

DOI: 10.1016/j.procir.2025.06.009

Google Scholar

[8] F. Böttcher, I. Schaarschmidt, J. Edelmann, A. Schubert, Simulation-Assisted Tool Design for Pulsed Electrochemical Machining of Magnetic Shape-Memory Alloys, J. of Manufacturing and Materials Processing 8 (2024).

DOI: 10.3390/jmmp8020046

Google Scholar

[9] I. Schaarschmidt, M. Hackert-Oschätzchen, G. Meichsner, P. Steinert, M. Zinecker, A. Schubert, Working Gap Analysis in Electrochemical Precision Machining of External Geometries with Ring Cathodes, Procedia CIRP 95 (2020) 662-667.

DOI: 10.1016/j.procir.2020.02.279

Google Scholar

[10] R. Petermann, P. Clauß, G. Meichsner, F. Meyer, S. Nickel, M. Hackert-Oschätzchen, Analysis of repeatability for experimental characterization of lateral gap during Pulsed Electrochemical Machining, 21th International Symposium on Electrochemical Machining Technology (2025) 57-64.

DOI: 10.1016/j.procir.2025.06.009

Google Scholar

[11] G. Meichsner, A. Schubert, Entwicklung und Realisierung einer Methode zur Bestimmung von Prozesseingangsgrößen für das elektrochemische Präzisionsabtragen, PhD Thesis, Scripts Precision and Microproduction Engineering 12 (2018), ISBN 9783957350879.

DOI: 10.31030/3007935

Google Scholar

[12] H. Peng, L. Hu, L. Li, L. Zhang, X. Zhang, Evolution of the microstructure and mechanical properties of powder metallurgical high-speed steel S390 after heat treatment, Journal of Alloys and Compounds 740 (2018) 766-773.

DOI: 10.1016/j.jallcom.2017.12.264

Google Scholar