NON-TRADITIONAL MACHINING

Hybrid Electrochemical Processes

SURFACE ECG
SURFACE ECG
• Electrochemical grinding (ECG) utilizes a negatively charged abrasive
grinding wheel, electrolyte solution, and a positively charged workpiece.

• The process is, therefore, similar to ECM except that the cathode is a
specially constructed grinding wheel instead of a cathodic shaped tool like
the contour to be machined by ECM.

• In ECG, the non-conducting abrasive particles act as a spacer between the

wheel conductive bond and the anodic workpiece.

• Depending on the grain size of these particles, a constant interelectrode gap

(0.025 mm or less) through which the electrolyte is flushed can be
maintained.
THE ECG PROCESS COMPONENTS
THE MECHANISM OF MATERIAL REMOVAL IN ECG
THE MECHANISM OF MATERIAL REMOVAL IN ECG
• ECG is a hybrid machining process that combines MA and ECD. The machining rate,
therefore, increases many times; surface layer properties are improved, while tool
wear and energy consumption are reduced.
• Material is mainly removed by ECD, while the MA of the abrasive grits accounts for
an additional 5 to 10 percent of the total material removal.
• Removal rates by ECG are 4 times faster than by conventional grinding, and ECG
always produces burr-free parts that are unstressed.
• The volumetric removal rate (VRR) is typically 1600 mm3/min.
• the introduction of MA, by a rotary conductive abrasive wheel, enhances the ECD
process. The work of the abrasive grains performs the mechanical depolarization by
abrading the possible insoluble films from the anodic workpiece surface.
THE DIFFERENT ECG APPLICATIONS
• Machining parts made from difficult-to-cut materials, such as sintered
carbides, creep-resisting (Inconel, Nimonic) alloys, titanium alloys,
and metallic composites.
• Applications similar to milling, grinding, cutting off, sawing, and tool
and cutter sharpening.
• Production of tungsten carbide cutting tools, fragile parts, and thin
walled tubes.
• Removal of fatigue cracks from steel structures under seawater.
• Producing specimens for metal fatigue and tensile tests.
• Machining of carbides and a variety of high-strength alloys.
THE ADVANTAGES OF ECG
• Absence of work hardening.

• Elimination of grinding burrs.

• Absence of distortion of thin fragile or thermosensitive parts.

• Good surface quality.

• Production of narrow tolerances.

• Longer grinding wheel life.

THE DISADVANTAGES OF ECG
• Higher capital cost than conventional machines

• Process limited to electrically conductive materials

• Corrosive nature of electrolyte

• Requires disposal and filtering of electrolyte

THE MAIN ELEMENTS OF ECH SYSTEM
• Electrochemical honing (ECH) combines the high removal characteristics of
ECD and MA of conventional honing. The process has much higher removal
rates than either conventional honing or internal cylindrical grinding.

• The machining system employs a reciprocating abrasive stone (with metallic

bond) carried on a spindle, which is made cathodic and separated from the
workpiece by a rapidly flowing electrolyte. In such an arrangement, the
abrasive stones are used to maintain the gap size of 0.076 to 0.250 mm.

• The material removal rate for ECH is 3 to 5 times faster than that of
conventional honing and 4 times faster than that of internal cylindrical
grinding. Tolerances in the range of ±0.003 mm are achievable,
THE MAIN ELEMENTS OF ECH SYSTEM
THE EFFECTS OF (ECH) ON BORE ERRORS
THE VIBRATORY SUPERFINISHING PROCESS
THE VIBRATORY SUPERFINISHING PROCESS
• Conventional superfinishing by vibration grinding is a micro-
finishing operation in which the surface micro-irregularities are
removed by the continuous and slow reciprocation of abrasive
sticks that move along the workpiece length.

• The sticks oscillate concurrently with short and rapid strokes with a
continuously revolving workpiece as. This process is however
known to sustain some of the surface micro-irregularities such as
waviness and out of roundness.
ELECTROCHEMICAL SUPERFINISHING (ECS)
• the combination of electrolytic dissolution (ECD) and mechanical
scrubbing (MS) improves the performance of the conventional
superfinishing process.
• As a result of such a combination, the dissolution process assists
the small stock removal rate due to the mechanical chipping
action.
• Higher stock removal rates become achievable using a separate
cathodic tool electrode, or a diamond abrasive stick with a
metallic bond.
ELECTROCHEMICAL SUPERFINISHING (ECS)
THE ELECTROCHEMICAL BUFFING (ECB) PROCESS
• Mechanical buffing is a slow finishing process used for achieving
smooth, bright, and mirror like surfaces.
• The process is carried out under dry conditions, which raises dust
and makes the working environmental conditions unsuitable.
• Electrochemical buffing (ECB), uses a carbon fiber cloth that rubs
the anodic specimen against a revolving cathode fiber buff.
• Electrolytes of NaCl or NaNO3 are supplied to the machining zone
using a suitable pump. The machining current flows from the
workpiece to the cathode through the carbon cloth.
THE ELECTROCHEMICAL BUFFING (ECB) PROCESS
THE END