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Electrochemical Machining

Electrochemical machining uses an electrolyte and electrical current to remove metal atoms from a workpiece, allowing for complex shapes to be machined with a burr-free surface regardless of the workpiece's strength or hardness. The process involves connecting a tool, made of a conductive material, to a power supply to act as the cathode while the workpiece acts as the anode. An electrolyte is circulated between the tool and workpiece to conduct current and ionize metal atoms from the workpiece as it is eroded to the shape of the tool. Electrochemical machining can machine complex internal cavities and is often used for duplication or shaping brittle materials that may crack during other machining methods.

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54 views7 pages

Electrochemical Machining

Electrochemical machining uses an electrolyte and electrical current to remove metal atoms from a workpiece, allowing for complex shapes to be machined with a burr-free surface regardless of the workpiece's strength or hardness. The process involves connecting a tool, made of a conductive material, to a power supply to act as the cathode while the workpiece acts as the anode. An electrolyte is circulated between the tool and workpiece to conduct current and ionize metal atoms from the workpiece as it is eroded to the shape of the tool. Electrochemical machining can machine complex internal cavities and is often used for duplication or shaping brittle materials that may crack during other machining methods.

Uploaded by

fr hedaiat
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© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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Electrochemical Machining

Electrochemical Machining

Electrochemical Machining





Uses an electrolyte and electrical


current to ionize and remove metal
atoms
Can machine complex cavities in highstrength materials
Leaves a burr-free surface
Not affected by the strength, hardness
or toughness of the material

Electrochemical Machining

Electrochemical Machining


As the tool approaches


the work piece it erodes
the negative shape of it.
Thus complex shapes
are made from soft
copper metal and used
to produce negative
duplicates of it. This
process
is
called
electrochemical sinking

Operating Principle


The tool may also be connected to a CNC


machine to produce even more complex shapes
with a single tool.

Main Subsystems





The power supply.


The electrolyte circulation system.
The control system.
The machine.

ECM Components
(Power)





The power needed to operate the ECM is


obviously electrical.
There are many
specifications to this power.
The current density must be high.
The gap between the tool and the work
piece must be low for higher accuracy, thus
the voltage must be low to avoid a short
circuit.
The control system uses some of this
electrical power.

ECM Components
(electrolyte circulation system)


The electrolyte must be injected in the


gap at high speed (between 1500 to
3000 m/min).
The inlet pressure must be between
0.15-3 MPa.
The electrolyte system must include a
fairly strong pump.
System also includes a filter, sludge
removal system, and treatment units.
The electrolyte is stored in a tank.

ECM Components
(control system)


Control parameters include:


Voltage
 Inlet and outlet pressure of electrolyte
 Temperature of electrolyte.


The current is dependant on the above


parameters and the feed rate.

ECM Components
(machine)


The machine is a major subsystem of the


ECM.
It includes the table, the frame, work
enclosure (prevents the electrolyte from
spilling), the work head (where the tool
is mounted)
The tools (electrodes) are also part of the
machine system

Advantages







There is no cutting forces therefore


clamping is not required except for
controlled motion of the work piece.
There is no heat affected zone.
Very accurate.
Relatively fast
Can machine harder metals than the tool.

disadvantages









More expensive than conventional


machining.
Need more area for installation.
Electrolytes may destroy the equipment.
Not environmentally friendly (sludge and
other waste)
High energy consumption.
Material has to be electrically
conductive.

Applications






The most common application of ECM is high


accuracy duplication. Because there is no tool
wear, it can be used repeatedly with a high
degree of accuracy.
It is also used to make cavities and holes in
various products.
Sinking operations (RAM ECM) are also used as
an alternative to RAM EDM.
It is commonly used on thin walled, easily
deformable and brittle material because they
would probably develop cracks with
conventional machining.

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