Due to unique advantages of Jet Electrochemical Machining (Jet‐ECM) such as the absence of mechanical and thermal effects, there is an increasing demand for the implementation of the technology in industrial sectors. However, meeting the stringent quality requirements of the current technological level is a challenge in Jet‐ECM especially for complicated microstructures. Hence, the implementation of an adequate metrology system is necessary to minimise deviations and to enhance the process towards zero‐defect‐manufacturing. The metrology system should be capable of measuring the workpiece before machining in order to enable the machine to adjust the process parameters and to reach the desired micro‐structure. Post‐machining measurements to compare the machined part with the desired shape should be possible as well. This will enhance the machine to make corrections on the workpiece before delivery to the next section in a process chain. However, in order to reach the desired microstructures, the characteristics of workpiece like material properties and previously machined structures on the size and shape of the machined microstructure should be taken into consideration. This is done through the implementation of results of the fingerprint study into the process control. In this study the effects of previously machined single grooves which intersect the secondly machined groove on the size, shape and surface roughness are investigated. The previously machined groove was generated by milling or Jet‐ECM. Since at the intersections the gap size changes and this lead to changes in current and current density, it is expected to observe changes in size and surface roughness. This investigation will show how grooves change at the intersections and whether the mentioned changes are significant. Besides, some suggestions will be provided in order to minimise the effects in Jet‐ECM of intersecting single grooves.

Due to unique advantages of Jet Electrochemical Machining (Jet‐ECM) such as the absence of mechanical and thermal effects, there is an increasing demand for the implementation of the technology in industrial sectors. However, meeting the stringent quality requirements of the current technological level is a challenge in Jet‐ECM especially for complicated microstructures. Hence, the implementation of an adequate metrology system is necessary to minimise deviations and to enhance the process towards zero‐defect‐manufacturing. The metrology system should be capable of measuring the workpiece before machining in order to enable the machine to adjust the process parameters and to reach the desired micro‐structure. Post‐machining measurements to compare the machined part with the desired shape should be possible as well. This will enhance the machine to make corrections on the workpiece before delivery to the next section in a process chain. However, in order to reach the desired microstructures, the characteristics of workpiece like material properties and previously machined structures on the size and shape of the machined microstructure should be taken into consideration. This is done through the implementation of results of the fingerprint study into the process control. In this study the effects of previously machined single grooves which intersect the secondly machined groove on the size, shape and surface roughness are investigated. The previously machined groove was generated by milling or Jet‐ECM. Since at the intersections the gap size changes and this lead to changes in current and current density, it is expected to observe changes in size and surface roughness. This investigation will show how grooves change at the intersections and whether the mentioned changes are significant. Besides, some suggestions will be provided in order to minimise the effects in Jet‐ECM of intersecting single grooves.

Jet Electrochemical Machining (Jet-ECM) is a manufacturing technique that applies a free electrolyte jet to generate the desired shapes [1]. Since the principle of the technique is the same as other techniques of Electrochemical Machining where the material removal takes place based on the anodic dissolution of workpiece, the working distance, which is the distance between nozzle’s front surface and the workpiece surface, is one important parameter of the process. The working distance affects the current density and consequently the geometry removal. The control of the working distance can be done based on the data gathered before and during machining by surface measurement [2]. This measurement usually is done by using electrostatic probing to detect a limited amount of points of the initial workpiece surface. Since electrostatic probing is comparatively slow, laser triangulation represents an alternative technique to detect a larger amount of points before machining within significantly shorter time [3]. In addition to electrostatic probing and laser triangulation, the actual working distance can be measured during the machining process to realize constant working distance. This can be done by detecting electrical signals like the actual total current. This method can be combined with pre-machining measurement by laser triangulation in order to ensure the prevention of any collision between the nozzle and the workpiece. In this study, on-machine metrology techniques for measuring the working gap as well as current measurements will be compared. Besides, the advantages and disadvantages of these techniques will be systematized. In further studies, the possibility of combining the techniques will be investigated to enhance Jet-ECM with more accurate measurement techniques.

In Electrochemical Machining (ECM), where the material removal takes place based on the anodic dissolution of the workpiece material, the working distance is one of the most important parameters. Especially in Jet Electrochemical Machining (Jet-ECM), where a micro nozzle is moved over the initial surface of the workpiece in order to apply an electrolytic free jet to produce the desired shapes, the distance between the nozzle and the workpiece becomes even more important. On the one hand a small working distance is aspired to achieve high current densities resulting in a high efficiency of the process. On the other hand the working distance needs to be large enough to avoid damages on the micro nozzle caused by electrical discharges or mechanical contact. Hence, the adjustment of the working gap is essential to realize a precise, effective and secure Jet-ECM process. The control of the gap size is done based on the data gathered before machining by surface measurement. Until now, the initial surface has been detected by electrostatic probing through moving the nozzle stepwise to the work piece surface and detect the voltage drop between the nozzle and the work piece. With this strategy, only a limited number of points can be detected within adequate time. Hence, in most cases only three points of the initial surface are detected in order to adjust the working distance according to the planar inclination of the workpiece. The coordinates of the three detected points are used to calculate the normal vector of the initial surface. In recent studies, another strategy was analysed, which is realized by dividing the surface into smaller areas and respectively calculating the normal vector of each area in order to obtain more accurate data of the initial surface. A further strategy is to use probing along the machining path of the tool and to gather the coordinates of a number of points along the path. The above mentioned methods usually do not ensure the precise control of the gap size especially for the surfaces with complex geometry with locally confined convex and concave shapes and are highly affected by the size of the probe. In this study, the application of a laser scanner is investigated for the measurement of the workpiece surface before machining to gather the required data for the adjustment of the working distance during Jet-EC machining of complicated surfaces.

In Electrochemical Machining (ECM), where the material removal takes place based on the anodic dissolution of the workpiece material, the working distance is one of the most important parameters. Especially in Jet Electrochemical Machining (Jet-ECM), where a micro nozzle is moved over the initial surface of the workpiece in order to apply an electrolytic free jet to produce the desired shapes, the distance between the nozzle and the workpiece becomes even more important. On the one hand a small working distance is aspired to achieve high current densities resulting in a high efficiency of the process. On the other hand the working distance needs to be large enough to avoid damages on the micro nozzle caused by electrical discharges or mechanical contact. Hence, the adjustment of the working gap is essential to realize a precise, effective and secure Jet-ECM process. The control of the gap size is done based on the data gathered before machining by surface measurement. Until now, the initial surface has been detected by electrostatic probing through moving the nozzle stepwise to the work piece surface and detect the voltage drop between the nozzle and the work piece. With this strategy, only a limited number of points can be detected within adequate time. Hence, in most cases only three points of the initial surface are detected in order to adjust the working distance according to the planar inclination of the workpiece. The coordinates of the three detected points are used to calculate the normal vector of the initial surface. In recent studies, another strategy was analysed, which is realized by dividing the surface into smaller areas and respectively calculating the normal vector of each area in order to obtain more accurate data of the initial surface. A further strategy is to use probing along the machining path of the tool and to gather the coordinates of a number of points along the path. The above mentioned methods usually do not ensure the precise control of the gap size especially for the surfaces with complex geometry with locally confined convex and concave shapes and are highly affected by the size of the probe. In this study, the application of a laser scanner is investigated for the measurement of the workpiece surface before machining to gather the required data for the adjustment of the working distance during Jet-EC machining of complicated surfaces.

Jet Electrochemical Machining (Jet-ECM) is a manufacturing technique that applies a free electrolyte jet to generate the desired shapes [1]. Since the principle of the technique is the same as other techniques of Electrochemical Machining where the material removal takes place based on the anodic dissolution of workpiece, the working distance, which is the distance between nozzle’s front surface and the workpiece surface, is one important parameter of the process. The working distance affects the current density and consequently the geometry removal. The control of the working distance can be done based on the data gathered before and during machining by surface measurement [2]. This measurement usually is done by using electrostatic probing to detect a limited amount of points of the initial workpiece surface. Since electrostatic probing is comparatively slow, laser triangulation represents an alternative technique to detect a larger amount of points before machining within significantly shorter time [3]. In addition to electrostatic probing and laser triangulation, the actual working distance can be measured during the machining process to realize constant working distance. This can be done by detecting electrical signals like the actual total current. This method can be combined with pre-machining measurement by laser triangulation in order to ensure the prevention of any collision between the nozzle and the workpiece. In this study, on-machine metrology techniques for measuring the working gap as well as current measurements will be compared. Besides, the advantages and disadvantages of these techniques will be systematized. In further studies, the possibility of combining the techniques will be investigated to enhance Jet-ECM with more accurate measurement techniques.