Recent dynamic development of abrasive hybrid manufacturing processes results from application of a new difficult for machining materials and improvement of technological indicators of manufacturing processes already applied in practice. This tendency also occurs in abrasive machining processes which are often supported by ultrasonic vibrations, electrochemical dissolution or by electrical discharges. In the paper we present the review of new results of investigations and new practical applications of Abrasive Electrodischarge (AEDM) and Electrochemical (AECM) Machining.

The paper focuses on the fundamentals of electrochemical machining technology de-elopement with special attention to applications for micromachining. In this method, a material is removed during an anodic electrochemical dissolution. The method has a number of features which make it attractive technology for shaping parts with geometrical features in range of micrometres. The paper is divided into two parts. The first one covers discussion on: general characteristics of electrochemical machining, phenomena in the gap, problems resulting from scaling down the process and electrochemical micromachining processes and variants. The second part consists of synthetic overview of the authors’ research on localization of pulse electrochemical micromachining process and case studies connected with application of this method with use of universal cylindrical electrode-tool for shaping cavities in 1.4301 stainless steel. The latter application was conducted in two following variants: electrochemical contour milling and shaping carried out with sidewall surface of rotating tool. In both cases, the obtained shape is a function of electrode tool trajectory. Selection of adequate machining strategy allows to obtain desired shape and quality.

Cubic boron nitride (c-BN) is a “difficult-to-cut” material. High precision machining of this material is problematic because it is difficult to control the material removal rate and maintain acceptable accuracy. This paper describes an application of electrodischarge machining (EDM) for drilling micro holes in c-BN. The goal of this research was to determine a set of parameters and technical specifications for such a process. We used an isoenergetic transistor power supply with a microsecond voltage pulse generator and a tungsten tool electrode of diameter d = 381 μm. Each hole was drilled for 10 min. The holes did not exceed 410 μm in diameter and were at least 1000 μm deep. The process was carried out in a hydrocarbon dielectric liquid. We assess the quality of the holes from a qualitative and quantitative point of view. The results show that electrodischarge is a precise, accurate, and efficient method for machining c-BN.

The paper investigated an electrochemically-assisted microturning process. Depending on the variant of electrochemical assistance, material can be removed with simultaneous electrochemical and mechanical action or electrochemical assistance can change the conditions of the cutting by changing the mechanical properties of the machined material. The experimental part includes discussion of the study methodology and a comparison of straight turning results in the case of machining 1.4301 stainless steel with and without electrochemical assistance. Based on this study, we can confirm that electrochemical assistance brings significant benefits in both variants, especially when the depth-of-cut is in the range of 1 µm.

The paper concerns application of DPSS Nd: YAG 532nm pulse laser source for machining of polycrystalline WC based diamond inserts (PCD). The goal of the research was to determine optimal laser cutting parameters for cutting tool shaping. Basic criteria to reach the goal was cutting edge quality (minimalization of finishing operations), material removal rate (time and cost efficiency), choice of laser beam characteristics (polarization, power, focused beam diameter). The research was planned and realised and analysed according to design of experiment rules (DOE). The analysis of the cutting edge was prepared with use of Alicona Infinite Focus measurement system.