Abstract—Rotary Electrochemical Discharge Machining (RECDM) is an important manufacture technology in machining difficult-to-cut materials and to shape complicated contours and profiles with high material removal rate. This paper presents the physical and mathematical models for determination of the performance characteristics of RECDM. The results of experimental verification is also included. Index Terms—dissolution, discharges, removal rate, energy- consumption I. INTRODUCTION The technological improvement of machining processes can be achieved by combining different physical/chemical actions on the materials being treated. In particular a mechanical action, which is used in conventional material removal processes, can be combined with respective interactions applied in unconventional manufacturing processes such as electrical discharge machining (EDM), electrochemical machining (ECM), and laser beam machining (LBM). The reasons for developing a cross machining processes are to make use of the combined or mutually enhanced advantages, and to avoid or reduce some adverse effects the constituent processes produce when they are individually applied [1- 6]. Figure 1.Scheme of ECDM/ECAM In Figure 1 is shown schematic diagram of Electrochemical Discharge Machining (ECDM) or Electrochemical Arc machining (ECAM). Electrochemical Discharge Machining (ECDM) using pulse voltage and Electrochemical Arc Machining (ECAM) using constant or pulse voltage are the combined methods of Manuscript received July 19, 2012; revised August 7, 2012. J. Kozak is with the Institute of Advanced Manufacturing Technology, ul. Wroclawska 37A, 30-011Cracow and the Institute of Aviation, Al.Krakowska 110/114, 02-256 Warsaw Poland (corresponding author to provide phone fax: +48 22 846 44 32, e-mail: jkozak64@wp.pl). M. Zybura is with the Institute of Advanced Manufacturing Technology, ul. Wroclawska 37A, 30-011Cracow Poland, (e-mail: Maria.Zybura@ios.krakow.pl) machining involving ECM and EDM. Electrochemical Machining (ECM) is characterized by high surface integrity, improved surface finish, high machining rate, and the absence of tool-electrode wear. But as compared with EDM, it has low accuracy of reproduction of the tool electrode shape into the workpiece. Electrical Discharge Machining (EDM) can provide a high surface finish and high machining accuracy only with a low productivity. An increase in the EDM rate result in a significantly higher roughness and deeper damaged surface layer. However, a reduction in surface roughness leads to increased of the tool electrode wear. A combination of ECM with EDM in one process ECDM/ECAM in an electrolyte solution (such as NaNO 3 , NaCl), has shown to contain the benefits of both processes, provided that the parameters of the combined process are properly selected. The process yields rates of material removal that can be as much as five to fifty times greater than ECM and EDM respectively [1-4]. Applications in which a combined form of both processes has been used in hole drilling, die sinking [3, 4], and cutting [6]. The ECDM/ECAM/ are especially effective when dealing with materials with tensile strength higher than 1500 N/mm 2 and heat resistance alloys. Machining capacity of the order 10 4 mm 3 /min, accuracy of 0.02-0.2 mm and surface roughness of Ra = 1.25-2.5 m are obtained. Figure 2. Schematic diagram of Rotary Electrochemical Discharge Machining Mathematical Modeling of Rotary Electro Chemical Discharge Machining (RECDM) J. Kozak Member, IAENG, and M. Zybura Proceedings of the World Congress on Engineering and Computer Science 2012 Vol II WCECS 2012, October 24-26, 2012, San Francisco, USA ISBN: 978-988-19252-4-4 ISSN: 2078-0958 (Print); ISSN: 2078-0966 (Online) WCECS 2012