What is overcut and how does it affect the form and tolerance of a cut?
Overcut is defined as material that is removed beyond the shape of the grinding wheel. The overcut results from the path of the electrolyte around the wheel within the electrical field created in the cut. A higher voltage creates a larger electrical field which allows the electrolyte to remove more material beyond the wheel profile. The electrolyte flow and pressure also have a large impact on the form of the cut. Higher flow will allow the electrolyte to remove more metal within the electrical field than a lower flow. The ideal flow pattern would be a uniform film of electrolyte in the exact shape of the wheel in the cut. This can never be fully achieved because of the high wheel speeds and centrifugal force of the electrolyte on the wheel. In addition, the profile of the cut will usually disturb the electrolyte flow to some extent. A correct nozzle can be critical to getting the correct flow pattern on the wheel.
