The basis of a technique for in-line process characterization of electrochemical machining (ECM) has been established. This technique has been applied to map out parameter interdependence, resulting from non-ideal conditions, in the form of the C-function. This mapping is achieved within a single characterization trial taking only a few minutes to complete, thus avoiding the need for extensive iterative trials, as has previously been the case. This approach has been made possible through the novel use of an ultrasonic time-of-flight system to allow the spatial measurement of erosion parameters. Example C-functions are generated for the case of an Inconel 718/sodium nitrate system. This methodology is shown to apply to the characterization of the machining of both planar and two-dimensional double-cosine profiles under non-ideal conditions. This is an important step towards the implementation of a fully automated process specification procedure for ECM.
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