Abstract
Electrochemical honing (ECH) is an electrolytic precision mircofinsihing technology based on the hybridization of the electrochemical machining and conventional honing process principles to provide the controlled functional surface generation and fast material removal capabilities in a single action. This paper presents the distinctive findings of comprehensive experimental investigations designed to explore the influence of key ECH process parameters on the work surface microgeometrical, part-macrogeometrical, and material removal aspects. The current intensity, electrolyte concentration, stick-out pressure, and stick grit size are found to be the major players in the process. Interactions between current intensity, electrolyte concentration, and speed ratio play a vital role, specifically for macrogeometrical performance. Proper electrolyte composition and stick grit-size selections and a distinct coordination of electrolytic dissolution and mechanical scrubbing are crucial for the optimal performance. Work surface characterization reveals a nano-finished plateau-honed work surface featured with a uniform roughness value, impressive surface characteristic parameters, no trace of cold-worked material, or any adverse effect of the process. This, accompanied with precise part macro- geometry, can result in an unexcelled tribological performance of the components. Key features of an ECH set-up that was designed and developed incorporating several unique features are also highlighted.