Non-Traditional Machining

Module-2
ELECTRO CHEMICAL MACHINING
Presented by
Satish.P
M.Tech
GT & TC,
Bangalore - 560010
 ELECTRO CHEMICAL MACHINING
• ECM use electrical energy to remove material. This
group is identified by the term electrochemical
processes, because electrical energy is used in
combination with chemical reactions to accomplish
material removal.
• ECM is a nontraditional machining process of
removing metal from extremely hard materials using
a high current between the electrolyte (tool piece)
and work piece.
• 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.
• Uses an electrolyte and electrical current to ionize
and remove metal atoms.
• Can machine complex cavities in high-strength
materials.
• Leaves a burr-free surface.
 Classification of ECM process
• Electrochemical Grinding Process
• Electro Chemical honning
• Electrochemical deburring
• Electrochemical Turning Process
• Electrochemical Milling Process
• Electrochemical Wire Cutting
• Electrochemical Hole Drilling
• Two metallic bars arc immersed in the electrolytic solution
(electrolyte)The electrolyte is a salt solution like sodium
chloride or sodium nitrate mixed in water, and acts as a current
carrier.
• Both the metal bars are fastened to the positive and negative
lead of a battery. When the circuit is closed, direct current will
pass through the electrolyte between the bars of metal.
• Chemical reaction in the electrolyte transfers metal in solution
from the anode metallic bar and plated on the cathode metallic
bar. However, moving metal in a solution from one bar to the
other cannot be called machining.
• To be classified as machining, it is necessary to modify and
control the electrolytic process to produce specific shapes and
dimensional limits.
• This is precisely what is done in electrochemical machining
process.
• In electrochemical machining, the work piece forms
the anode, and a properly insulated tool having shape
similar to that desired in the work piece forms the
cathode.
• The tool and work piece are positioned closer to each
other with a conductive electrolyte flowing through a
small gap between the work piece and the tool.
• The chemical properties of the electrolyte are such
that, the constituents of the work piece material
(anode) go into the solution during electrolysis but do
not plate on the tool (cathode).
• The shape obtained in the work piece material is
exactly similar to the shaped tool.
• Basically in electroplating, the metal is deposited on the
work piece, while in ECM, the objective is to remove the
metal from the work piece.
• So, the reverse of electroplating is applied in ECM process.
• Therefore, the work piece is connected to positive
terminal (anode) and the tool is connected to negative
terminal (cathode).
• When the current is passed, the work piece loses metal
and the dissolved metal is carried out by circulating an
electrolyte between the work and tool.
Working Principle Of ECM
 Constuction
• The schematic arrangement of ECM process is shown in
fig.
• It consists of work piece, tool, servomotor for controlled
tool feed, D.C power supply, electrolyte, pump, motor
for pump, filter for incoming electrolyte and reservoir for
electrolyte.
• A shaped tool (electrode) is used in this process, which is
connected to negative terminal (cathode) and the work
piece is connected to positive terminal (anode).
• The tools used in this process should be made up of the
materials which have enough thermal and electrical
conductivity, high chemical resistance to electrolyte and
adequate stiffness and machinability.
• The widely used tool materials are stainless steel,
titanium, brass and copper.
• The tool is of hollow tabular type as shown in fig. and
an electrolyte is circulated between the work and tool.
• Most widely used electrolyte in this process is sodium
nitrate solution. Sodium chloride solution in water is a
good alternative but it is more corrosive than the
former. Some other chemicals used in this process are
sodium hydroxide, sodium sulphate, sodium flouride,
potassium nitrate and potassium chloride.
• Servomotor is used for controlling the tool feed and
the filter is used to remove the dust particles from the
electrolytic fluid.
 Working
• The tool and wor kpiece are held close to each other with a very
small gap (0.05 to 0.5mm ) between them by using servo motor.
• The electrolyte from the reservoir is pumped at high pressure
and flows through the gap between the work piece and tool at a
velocity of 30 to 60 m/s
• A mild D.C. voltage about 5 to 30 volts is applied between the
tool and work piece.
• Due to the applied voltage, the current flows through the
electrolyte with positively charged ions and negatively charged
ions. The positive ions move towards the tool (cathode) while
negative ions move towards work piece (anode)
• The electrochemical reaction takes place due to this flow of
ions and it causes the removal of metal from the work piece in
the form of sludge.