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ECM

The document discusses Electro Chemical Machining (ECM), a non-traditional machining process that removes material atom by atom using a conducting electrolyte. It highlights the importance of controlling electrolyte temperature and provides details on tool materials, electrode feed rates, and metal removal rates (MRR). Despite high installation costs, ECM is economically justified due to the quality of the products it produces.

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7 views2 pages

ECM

The document discusses Electro Chemical Machining (ECM), a non-traditional machining process that removes material atom by atom using a conducting electrolyte. It highlights the importance of controlling electrolyte temperature and provides details on tool materials, electrode feed rates, and metal removal rates (MRR). Despite high installation costs, ECM is economically justified due to the quality of the products it produces.

Uploaded by

atifexergic
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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8 ynconventional/Non-Traditional Machining processes 1 ELECTRO CHEMICAL MACHINING (Ect) al removal occurs atom by atom in the ECM process, which is the inverse of el i slow volage, high Curent process, Material removal is prepmeyne to there ee ra olyte temperature. The electrolyte temperature must be precisely Controlled because a 5°C increase in ature results aa 0.2mm ere ‘A conducting electrolyte is supplied within the machining area via a the tool. Insulation i provided on the tol’ side so thatthe reaction dows ny i i se pole to taper (Fig. 8.2) occur sideways, causing Bectrolyie NaCl, Nacio, Sudge Fig. 8.1: ECM Setup Overcut Fig. 8.2: Over Cut After ECM Tool Material used: Brass, Bronze, Copper, Aluminium, Gap between electrode and work piece: 0.03 — 0.5 mm * Centre line average value (R,): 0.2 - 0.8 p's Fe Fe? +2e~ 2e7 + 2H20 + H2T + 20H~ NaCl ~ Na’ +c Fe** + 20H” > Fe (OH); 1 Although ECM installations are very expensive but its operational cost is very low and economics is “stified by the quality product it produces. Mass of material removal oc charge ‘Production tngineenng » Mass Mass Zz Z = Electrochemical Equivalent F = Paraday’s constant = 96500, wqant ~au e ¢ = Chemical equivalent (Atomic weight/valency) 1 = Current passed (Amp) C= tme( seconds) Metal Removal Rate (MRR) e s Electrode feed rate ! = = $1 (em sec) Fp = density, gm/cm? = Specific material removal rate(MRR) = fs =Sxs = current density = av R ee Pea electrical resistivity Av ps! Gap between tool and work piece. Example 1: Calculate the MRR and electrode feed rate when copper is electrochemically machined Under following conditions. ps AV I Tool gap Atomic Weight Valency p MRR = 5Qem 18V 500A Tool 0.5mm 56 =2 = 7.8 glem3

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