Electrochemical
Machining (ECM)
and Grinding
Electrochemical
Machining
This process is reversal of the electro plating
Electrolyte acts as current carrier
High rate of electrolyte movement in tool work piece gap washes
metal ions away from the work piece ( ANODE)
This is washed just before they have a chance to plate on the tool
( cathode)
Shaped tool made of brass , copper , bronze , or stainless
steel
Electrolyte is pumped at a high rate through the passages in the
tool
Machines having current capacities as high as 40,000 A and as
2
low as 5A are available
Electrochemical
Machining
The operation of the ECM process is at low voltage (5 V to about
25 V) and very heavy current up to 40,000 ampere
Electrode control device which is housed in the ram works on the
servo-system.
Electrolyte circulation unit consists of a pump, filtration unit and
storage tank.
Normally, the gap between the tool and the work-piece is of the
order of 0.25 mm to 1 mm.
Process capabilities
Used to machine complex cavities in high strength
material
Applications in aerospace industry, jet engines parts
and nozzles
ECM process gives a burr free surface
No thermal damage
Lack of tool forces prevents distortion of the part
No tool wear
Capable of producing complex shapes and hard
materials
Electrochemical
Machining
Fig : Schematic illustration of the electrochemical-machining
process. This process is the reverse of electroplating.
5
Electrochemical
Machining
Operating Principle
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
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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.
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ECM Components
(electrolyte circulation
system)
The electrolyte must be injected in the
gap at high speed (between 20 to 30 m/s).
The inlet pressure must be between 2 to
35 kg/cm .
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.
2
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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.
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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
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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.
14
Advantages over EDM
Faster than EDM
No tool wear at all.
No heat affected zone.
Better finish and accuracy.
15
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.
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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.
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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Economics
The process is economical when a large
number of complex identical products
need to be made (at least 50 units)
Several tools could be connected to a
cassette
to
make
many
cavities
simultaneously. (i.e. cylinder cavities in
engines)
Large cavities are more economical on
ECM and can be processed in 1/10 the
time of EDM.
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Products
The two most common products of ECM are
turbine/compressor blades and rifle barrels. Each of
those parts require machining of extremely hard metals
with certain mechanical specifications that would be
really difficult to perform on conventional machines.
Some of these mechanical characteristics achieved by
ECM are:
Stress free grooves.
Any groove geometry.
Any conductive metal can be machined.
Repeatable accuracy of 0.0005.
High surface finish.
Fast cycle time.
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Safety Considerations
Several sensors are used to control short
circuit, turbulence, passivation, contact
and overcurrent sensors. In case of
contact, immense heat would be generated
melting
the
tool,
evaporating
the
electrolyte and cause a fire.
The worker must be insulated to prevent
electrocution.
The tool and the work piece must be
grounded
before
any
handling
is
performed.
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Safety Consideration
Hydrogen gas emitted is very flammable,
so it should be disposed of properly and
fire precautions should be taken.
The waste material is very dangerous
and environmentally unfriendly (metal
sludge) so it must be recycle or disposed
of properly.
Electrolyte is highly pressurized and
worker must check for minor cracks in
piping before operating.
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Characteristics of ECM
Material Removal
mechanism
: Electrolysis
Medium : Electrolyte (Sodium chloride, sodium nitrate,
sodium sulphate and potassium chloride.
Tool materials :Aluminium, Bronze, Carbon , Monel,
copper and brass
Work piece materials: conducting metals and alloys
Process parameters : current , voltage, feed rate and
electrolyte.
Application
: Machining of complex cavities and curved
shapes, straight hole drilling with side insulation
Limitation
:
Cannot
machine
electrically
non
conducting
materials, expensive equipment, very low
material removal rate.
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Electrolyte
The
main function of the electrolyte
in the ECM process are:
To conduct the current between the tool and the
work-piece,
To flush the products of machining, and
To dissipate heat produced during machining.
It will be seen from the above that the electrolyte
should have high electrical conductivity. in addition
to this, it should posses the following characteristics.
It should be as far as possible non-corroding and nontoxic.
It should be chemically and electro-chemically stable.
It should be available at reasonable price.
It should possess low-viscosity and high specific heat.
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Electrolyte
The electrolyte mostly used in the ECM process
is sodium chloride (NACL). Owing to its corrosive
effect, it presents some problems.
Other electrolytes used are sodium nitrate
(NaNO3)
Potassium chloride (KCL) and
sometimes mixtures of these electrolytes.
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Comparison of non conventional
machines
PROCESSE
S
MRR
Dimensio Surface
finish
(mm3/se nal
c)
Accuracy (m)
(m)
Power
consum
ption
kwh
Capital
cost
CHEMICAL
MACHININ
G
0.15-0.03 25-100
0.5-2.5
--
Mediu
m
ECM
200-300
15-100
0.1-2.5
100-150
Very
high
ULTRASON
IC
MACHININ
G
5-10
7-15
0.2-2.5
2-3
Low
15-50
0.2-2.5
2-4
Mediu
m
ELECTRICA 10-20
L
DISCHARG
E
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Electrochemical
Grinding
The abrasive grits protruding from the grinding wheel
at the contact with the work piece establish the gap
distance in ECG.
The electrolyte flows through the gap between the
grains to play its role in electrolysis.
Depleting is responsible for 95% or more of the metal
removal in ECG, and the abrasive action of the grinding
wheel removes the remaining 5% or less, mostly in the
form of salt films that have been formed during the
electrochemical reactions at the work surface.
Because most of the machining is accomplished by
electrochemical action.
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Electrochemical
Grinding
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Advantages of ECG
It has the ability to grind any electrically
conductive material regardless of hardness.
Metal removal rate for metals harder than
Rockwell C-60 is much higher compared to
milling, broaching or conventional grinding
processes.
The wheel life is longer; consequently
reducing down-time due to wheel dressing.
Surface finish is good and accuracy is high.
No distortion of fragile and thin parts.
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Disadvantages
High initial cost of equipment.
MRR
for
softer
metals
is
not
comparable
with
conventional
processes.
Only electrically conductive metals can
be machined.
The corrosive effects of chemicals used
on the machine and equipments needs
special precautions.
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