Manufacturing Processes -2

1
 Electrochemical Machining (ECM)
Electrochemical machining is one of the most unconventional machining processes.
▪ The process is actually the reverse of electroplating with some modifications.
▪ It is based on the principle of electrolysis.
▪ In a metal, electricity is conducted by free electrons but in a solution the conduction
of electricity is achieved through the movement of ions.
▪ Thus the flow of current through an electrolyte is always accompanied by the
movement of matter. 𝐴 = 𝜋𝑟 2
▪ In the ECM process the work-piece is connected to a positive electrode and the tool to
the negative terminal for metal removal.

Somashekara M A, ME 305 Manufacturing Processes -2,

 Electrochemical Machining (ECM)
With ECM the rate of metal removal is
independent of the work-piece hardness.
ECM becomes advantageous when either the
work material possesses a very low
machinability or the shape to be machined is
complex.
𝐴 = 𝜋𝑟 2

• Unlike most other conventional and unconventional processes, here there is practically no tool wear.
• Though it appears that, since machining is done electrochemically, the tool experiences no force, the
fact is that the tool and work is subjected to large forces exerted by the high pressure fluid in the gap.

Somashekara M A, ME 305 Manufacturing Processes -2,

 Electrochemical Machining (ECM)
▪ The dissolution rate is more where the gap is less and vice versa.
▪ This is because the current density is inversely proportional to the gap.
▪ Now, if the tool is given a downward motion, the work surface tends to take the same
shape as that of the tool, and at a steady state the gap is uniform.
▪ Thus the shape of the tool is represented in the job.
▪ In an electrochemical machining process, 𝜋𝑟 2electrolyte is pumped at a high pressure
𝐴 =the
through the tool and the small gap between the tool and the work-piece.
▪ The electrolyte is so chosen that the anode is dissolved but there is no deposition on
the cathode.
▪ The order of the current and voltage are a few 1000 amps and 8-20 volts. The gap is of
the order of 0.1-0.2mm .
▪ The metal removal rate is typically 1600 mm3/sec for each 1000 Amp.
▪ Approximately 3 KW-hr. are needed to remove 16000 mm3 of metal which is almost
30 times the energy required in a conventional process.
Somashekara M A, ME 305 Manufacturing Processes -2,
 𝐴 = 𝜋𝑟 2

Somashekara M A, ME 305 Manufacturing Processes -2,

▪ Let us take an example of machining of low carbon steel which is primarily a ferrous
alloy mainly containing iron. For electrochemical machining of steel, generally a
neutral salt solution of sodium chloride (NaCl) is taken as the electrolyte.
▪ The electrolyte and water undergoes ionic dissociation as shown below as
potential difference is applied
𝐴 = 𝜋𝑟 2

Somashekara M A, ME 305 Manufacturing Processes -2,

 ECM: Knee Implants

𝐴 = 𝜋𝑟 2

Somashekara M A, ME 305 Manufacturing Processes -2,

 ECM: Deep Hole Drilling

Gas Turbine blade air cooling hole

𝐴 = 𝜋𝑟 2

Fluorocarbon resin is coated on outer surface of Ti-CP pipe

Workpiece: Ti, Ni-Ti, Inconel, hastelloy, Ta, Nb, Au, Ag, Pt and
Zr

Somashekara M A, ME 305 Manufacturing Processes -2,

 𝐴 = 𝜋𝑟 2
Electro discharge machining (EDM)

Somashekara M A, ME 305 Manufacturing Processes -2,

 Electro discharge machining (EDM)
▪ The electrical discharge machining (EDM) process we know today started with the
observations of Joseph Preistly in 1770. He noticed that electrical discharges had
removed material from the electrodes in his experiments. This is also known as
electro-discharge erosion.
▪ In the 1940’s two Soviet researchers, the Lazarenkos’, developed a machining process
that formed the foundation for modern𝐴wire
= 𝜋𝑟EDM
2 and small hole EDM.
▪ EDM is also known as: spark machining, spark eroding, and die sinking.
▪ Electro Discharge Machining (EDM) is an electro-thermal non-traditional machining
process, where electrical energy is used to generate electrical spark and material
removal mainly occurs due to thermal energy of the spark.
▪ EDM is mainly used to machine difficult-to-machine materials and high strength
temperature resistant alloys. however, only electrically conducting/semi-conducting
materials can be machined by this process.

Somashekara M A, ME 305 Manufacturing Processes -2,

 Electro discharge machining (EDM)
▪ EDM can be used to machine difficult geometries in small batches or even on job-shop
basis.
▪ In EDM, a potential difference is applied between the tool and workpiece. Both the tool
and the work material are to be conductors of electricity.
▪ The tool and the work material are immersed in a dielectric medium. Generally
kerosene or deionised water is used 𝐴as=the 𝜋𝑟 2dielectric medium. A gap is maintained
between the tool and the workpiece. Depending upon the applied potential difference
and the gap between the tool and workpiece, an electric field would be established.
▪ There are certain materials like having very high hardness and having very high
toughness.
▪ Die materials with complicated shapes and hardness can be easily machined with
good surface finish at a reasonable surface finish and accuracy through this process

Somashekara M A, ME 305 Manufacturing Processes -2,

 Electro discharge machining (EDM)
▪ The EDM process is thus best suited for making intricate cavities and contours.
▪ EDM process is best suited for machining the following materials like hardened tool
steels, carbides, titanium, some super alloys like inconel, etc.
▪ The fine chips of material removed from the work piece gets flushed away by the
continuous flow of the dielectric fluid.
▪ The repetitive discharge creates a set of successively
𝐴= 𝜋𝑟 2 deeper craters in the work piece
until the final shape is reduced.

Somashekara M A, ME 305 Manufacturing Processes -2,

 Electro discharge machining (EDM)
▪ Pulsed discharges occur in the “gap” filled with an insulating medium, preferably a
dielectric liquid like hydrocarbon oil or de-ionized (de-mineralized) water between
tool electrode and workpiece.
▪ Electrical discharge machining process works on the basic principle of spark
generation and metal removed by spark erosion.
𝐴 = 𝜋𝑟 2

Somashekara M A, ME 305 Manufacturing Processes -2,

 Principle
▪ Initial electrons, are accelerated by the electric field and ionize the neutral species due
to collision, resulting in an electron avalanche.
▪ Thus, the electric field is distorted and streamers are developed toward both the
anode and cathode, resulting in an established discharge.
▪ In EDM, since discharge duration is normally over several µs and current density is
108-109A/m2, the established discharge 𝐴 =is𝜋𝑟
an2 arc discharge.
▪ The discharge is sustained by electron emission from the cathode spot which is due
not only to the secondary emission but also to the thermionic and field emissions.
▪ Thus the plasma is highly ionized resulting in high current densities with the
comparatively low discharge voltage of about 20 V. The discharge voltage is composed
of an anode, cathode and channel voltage drop, and its value will slightly change
depending on electrode materials, dielectric fluids, gap width and pulse conditions

Somashekara M A, ME 305 Manufacturing Processes -2,

▪ Precision machining of materials such as hardened steels, carbides, ceramics and any
other material that offers 0.01 S/cm of electrical conductivity

𝐴 = 𝜋𝑟 2

Somashekara M A, ME 305 Manufacturing Processes -2,

 EDM process

𝐴 = 𝜋𝑟 2

Somashekara M A, ME 305 Manufacturing Processes -2,

 3 Types of EDM Machines
▪ Die Sinker or “Ram” EDM
▪ Wire or “Cheese Cutter” EDM
▪ Hole Drilling or “Hole Popper” EDM

𝐴 = 𝜋𝑟 2

Somashekara M A, ME 305 Manufacturing Processes -2,

 Die Sinker or “Ram” EDM
▪ Conventional EDM is commonly known as Spark EDM. This process is often used when
the desired cut or design feature does not penetrate through the entire workpiece.
Electrodes for Spark EDM are mostly manufactured from graphite or copper tungsten.
RAM EDM electrodes utilize a negative-formed shape which contains all the detail of
the final workpiece.
𝐴 = 𝜋𝑟 2

Somashekara M A, ME 305 Manufacturing Processes -2,

 EDM: Sinking

𝐴 = 𝜋𝑟 2

80% of the form of the mould is machined by high-speed milling and 20% by EDM.

http://www.onaedm.com/

Somashekara M A, ME 305 Manufacturing Processes -2,

 EDM: Sinking

𝐴 = 𝜋𝑟 2

•Component material: nickel based alloys.

•Depth: from 3.50 to 5.50 mm.
•Width: 0.74 +/-0.10 mm.
•Cross section: from 40 to 80 mm2.
•Other: high precision requirements in the bottom radius.
•Electrode material: ultra-fine graphite.

Somashekara M A, ME 305 Manufacturing Processes -2,

 CNC-Wire EDM
▪ Wire EDM is also known as: wire-cut EDM, wire cutting, edm cutting, wire burning, wire
erosion, and ‘cheese-cutter’ EDM.
▪ The second type of electrical discharge machining is called wire EDM and is also known as
wire erosion, wire burning or spark EDM.
▪ In Wire EDM a thin wire (0.2 -0.4mm) is used to cut the work piece.
▪ In this case, the wire works as the electrode.2 During the machining, the wire is constantly
coming from an automated feed with a𝐴spool.
= 𝜋𝑟

▪ The wire is usually made of a single strand of brass, and is held at the top and bottom by
diamond guides, the guides can move in the x-y plane and the upper guide can move
independently in three axes.
▪ This allows for tapers and other complex, intricate and delicate shapes to be machined.
▪ The movement of the guides and the workpiece are controlled via the CNC computer.
▪ The typical wire diameter is 0.25mm in diameter and comes in spools that are about 10
miles long, the cut is larger than the diameter of the wire, since the wire does not actually
touch the work piece and “cutting” occurs due to the spark from the wire to the workpiece.
Somashekara M A, ME 305 Manufacturing Processes -2,
 Wire EDM

𝐴 = 𝜋𝑟 2

Somashekara M A, ME 305 Manufacturing Processes -2,

 𝐴 = 𝜋𝑟 2

Somashekara M A, ME 305 Manufacturing Processes -2,

 𝐴 = 𝜋𝑟 2

Somashekara M A, ME 305 Manufacturing Processes -2,

 𝐴 = 𝜋𝑟 2

Somashekara M A, ME 305 Manufacturing Processes -2,

 Hole Drilling or “Hole Popper” EDM
▪ Electrical discharge machining (EDM) drilling is a little more
complex than typical chip-removal processes.
▪ In EDM work, energy is directed into an electrode and the workpiece
is submerged in a dielectric fluid.
▪ When the two are separated by a small space—the spark gap—a
pulsed electrical discharge from the electrode 𝐴= creates
𝜋𝑟 2 a spark that
removes material from the workpiece through a process of melting
and evaporation.
▪ In typical applications, brass or copper electrodes with the correct
finish-hole diameter are used to create holes in the workpiece.
▪ The electrode is charged by the EDM power supply and is fed
forward to create the machining feed rate. The power usage and
electrode feed rate, as well as the motion of the machine's axes, are
all controlled by the machine's CNC.

Somashekara M A, ME 305 Manufacturing Processes -2,

Hole Drilling or “Hole Popper” EDM

𝐴 = 𝜋𝑟 2

Somashekara M A, ME 305 Manufacturing Processes -2,

Pros,
▪ It can be used to machine any material that is electrically conductive.
▪ It can easily machine thin fragile sections such as webs or fins without deforming the part.
▪ Complex dies sections and molds are produced accurately, faster and at lower price.
▪ It is burr-free process.
▪ It does not involve contact between the tool and workpiece. So delicate sections and work material can
be machined easily without any distortion.
▪ It can machined complex shapes which is not manufactured by the conventional machine tools.
▪ It can produce tapered holes. 𝐴 = 𝜋𝑟 2
Cons,
▪ It can machine only electrically conductive materials.
▪ Low rate of metal removal.
▪ More tool wear during machining.
▪ Takes extra cost and time for the preparing electrodes for ram/sinker EDM.
▪ High power consumption.
▪ Overcut is formed in EDM.

Somashekara M A, ME 305 Manufacturing Processes -2,

 Thank
𝐴 = 𝜋𝑟 you 2

Somashekara M A, ME 305 Manufacturing Processes -2,