الفهرس 
IntroductionOnly 14 pages are availabe for public view
 |  | from | 180 |  |  |
| | | from | 180 | | |
Abstract
The main objective of machining processes is to produce parts with a high accuracy and surface quality. Conventional machining utilizes cutting tools that must be harder than the workplace materials. The use of hard to cut materials encouraged efforts to discover non-conventional machining processes that are well-established in modern manufacturing industries.
Electrochemical machining ECM is a technology that has many potential advantages for the machining of these advanced materials. Unlike many conventional metal shaping processes, ECM is able to machine hard materials and complex shapes with acceptable quality and high metal removal rates.
Electrochemical honing ECH conbines the high removal characteristics of electrochemical of electrochemical dissolution ECD and mechanical abrasion MA of conventional honing. The process has much higher removal rates than either conventional honing or internal cylindrical grinding.
Although many researchers apply ECM to many fields, very few researchers have studied the effect of working conditions on ECH process but very few researchers applied statistical models to predict the best working conditions using ECH process.
Hence, one of our aims in this work is to study the effect of working conditions, using ECH technique for finishing of internal bores. So a special designed test reg, which was developed in the laboratory, has been used to carryout the current experiments. The studied working conditions were workpiece material, maching time, intial working gap, tool rotational speed, tool tip shape, electrolyte type, electrolyte concentration and applied current.
The other aim of our work is to apply a statistical analysis to predict working conditions. To achieve this aim, software has been established and employed. The software was fully developed in-house through this work and was named ECHPro Electro Chemical Honing Program. It was written using Matlab V7.2 providing a friendly graphical user interface GUI.
The main advantages of the ECHpro software is its ability to predict average surface roughness R, peak-to-valley height, and metal removal rate MRR according to the desired working conditions. Beside that, the software has the ability tp present the relationships between any of the studied parameters in 2D graphs. The most effective advantages which is needed in industry, is that the software has the ability to suggest the optimal working conditions for the desired value of r, or r or MRR.
The experimental work was executed using round specimens with coaxial hole machined by internal operations to reach initial average surface for the hole.
The experiments using the designed ECH test rig at different working conditions were done. The relation between the roughness parameters and MRR with the working conditions was studied for R,R,MRR, two results were obtained from excel for each working conditions, which are; the equation of the correlation coefficient of these equation. These results were used to build up the ECHPro . equations database so that it can predict the working conditions for other similar specimens.
The accuracy of the program was verified by predicting the working conditions of the used test samples, which were machined by known working conditions. The verification proved that an error within the range pf 9 for R and 12 % for R and 8% MRR was obtained when applying the proposed software compared with experimental results.