CNC & Superalloy Prepress

Electrochemical Grinding (ECG) & Electrolytic Deburring Calculator

Determine Faraday dissolution rates, current densities (15–40 A/cm²), insulating diamond standoff gaps, and burr-free CNC feed paths for medical needles, honeycombs, and aerospace alloys.

1. Input Parameters

Workpiece Superalloy / Metal

DC Generator Current (I) [Amperes]

Direct current supplied across cathode conductive wheel and anodic workpiece.

Grinding Contact Interface Area (A) [cm²]

Projected contact area between diamond grit wheel rim and metal surface.

Diamond Abrasive Grain Protrusion (g) [µm]

Insulating grit height establishing physical electrolyte gap between metal bond and workpiece.

2. Calculation Results

Current Density (J)

0.0 A/cm²

Electrochemical MRR (Q_ec)

0.0 mm³/min

Mechanical vs Anodic Dissolution

90% / 10%

Max Burr-Free Feed Speed (v_f)

0.0 mm/min

3. Geometric Visualizer

Tooling & Vector Prepress Engineering Notes

Electrochemical Grinding (ECG) Principles: In ECG, approximately 90% of material removal occurs through Faraday anodic dissolution in a conductive sodium nitrate ($ ext{NaNO}_3$) electrolyte, while non-conductive diamond or CBN abrasive grains remove the passive oxide layer without generating grinding burrs, thermal recasting, or work hardening.

Vector Toolpath Calibration: Ensure CNC lead-in motions account for diamond protrusion standoff gap (typically 20–30 µm). Plunge cycles must maintain constant current density (15–35 A/cm²) to avoid abrasive glazing or mechanical spindle stalling.