Abstract: Arming to on-line measuring inter-electrode gap, 6D forces acting on cathode through electrolyte are acted as research parameters. Two kinds of experimental plannings such as monitoring forces without machining current and monitoring in really machining condition are designed, and the relation between 6D forces and interelectrode gap is analyzed form quality and quantity facet respectively. Machining experiments using three kinds of cathode profile such as plane, slant and blade surface are researched, and the plane and slant equations between 6D forces and inter-electrode gap will be set up based on the principle of least square multi-variables linear iteration method. Furthermore, experimental data of blade machining are used to check up and modify the acquired equations. At last, the modified equations will be set up. The relation between each parameter in equations is analyzed and such conclution is drawn: Under 15% error range, the equation can be used to on-line monitor the interelectrode gap of ECM.

Key words: Electrochemical machining (ECM), 6D forces, Interelectrode gap Experimental research