The effect of the tool-bottom insulation layer on machining performance in electrochemical mill-grinding is investigated by performing the bottom insulation design for a tool substrate with both the outer diameter and the cutting depth of 10mm. The results show that it can significantly improve the overcut

flatness and surface quality of the slot bottom by using the abrasive tool with bottom insulation. Under an applied voltage of 30V

a cutting depth of 10mm and a feed rate of 2.7mm/min

etc

the average slot depth

the maximum difference in bottom profile coordinates and the surface roughness obtained with the uninsulated tool are 10.61mm

783.9μm and 1.705μm

but they are only 10.32mm

352.5μm and 0.811μm with the insulated tool

respectively.