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    Working Principle of Ecm Working Principle of Ecm Electrochemical Machining (Ecm) Electrochemical Machining (Ecm)

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    Konda Reddy
    Electrochemical machining (ECM) is a non-traditional machining process that removes metal by an electrochemical dissolution process based on Faraday's Laws of Electrolysis. In ECM, a tool acts as a cathode and the workpiece as an anode. An electric current is passed through an electrolyte solution, chemically removing small amounts of metal from the workpiece. ECM can machine hard metals and intricate shapes and is used for machining difficult-to-machine alloy parts for aerospace, nuclear, and other applications. The document discusses the working principle, electrolyte types, current density distribution, modes of electrolyte flow, and applications of ECM.

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    © All Rights Reserved
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    Working Principle of Ecm Working Principle of Ecm Electrochemical Machining (Ecm) Electrochemical Machining (Ecm)

    Uploaded by

    Konda Reddy
    89 views7 pages
    Electrochemical machining (ECM) is a non-traditional machining process that removes metal by an electrochemical dissolution process based on Faraday's Laws of Electrolysis. In ECM, a tool acts as a cathode and the workpiece as an anode. An electric current is passed through an electrolyte solution, chemically removing small amounts of metal from the workpiece. ECM can machine hard metals and intricate shapes and is used for machining difficult-to-machine alloy parts for aerospace, nuclear, and other applications. The document discusses the working principle, electrolyte types, current density distribution, modes of electrolyte flow, and applications of ECM.

    Original Description:

    Electro chemical machining

    Original Title

    ECM and ECD

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    Electrochemical machining (ECM) is a non-traditional machining process that removes metal by an electrochemical dissolution process based on Faraday's Laws of Electrolysis. In ECM, a tool acts as a cathode and the workpiece as an anode. An electric current is passed through an electrolyte solution, chemically removing small amounts of metal from the workpiece. ECM can machine hard metals and intricate shapes and is used for machining difficult-to-machine alloy parts for aerospace, nuclear, and other applications. The document discusses the working principle, electrolyte types, current density distribution, modes of electrolyte flow, and applications of ECM.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    89 views7 pages

    Working Principle of Ecm Working Principle of Ecm Electrochemical Machining (Ecm) Electrochemical Machining (Ecm)

    Uploaded by

    Konda Reddy
    Electrochemical machining (ECM) is a non-traditional machining process that removes metal by an electrochemical dissolution process based on Faraday's Laws of Electrolysis. In ECM, a tool acts as a cathode and the workpiece as an anode. An electric current is passed through an electrolyte solution, chemically removing small amounts of metal from the workpiece. ECM can machine hard metals and intricate shapes and is used for machining difficult-to-machine alloy parts for aerospace, nuclear, and other applications. The document discusses the working principle, electrolyte types, current density distribution, modes of electrolyte flow, and applications of ECM.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 7

    9/12/2019

    1 2

    WORKING PRINCIPLE OF ECM ELECTROCHEMICAL MACHINING (ECM)

    FARADAY’ S LAWS OF ELECTROLYSIS

    m a itE

    MASS OF DISSOLVED METAL GRAM CHEMICAL EQUIVALENT = A / Z

    CURENT TIME
    AATOMIC MASS OF ANODE, Z  VALENCY OF DISSOLUTION OF ANODE

    ELECTROCHEMICAL ENERGY DETACHES METAL FROM ANODE ATOM BY


    3 ATOM THAT IS WHY IT IS AN IMPORTANT PROCESS FOR 4
    MICROMANUFACTURING

    1
    9/12/2019

    ELECTROCHEMICAL REACTIONS CURRENT DENSITY DISTRIBUTION


    TYPES OF ELECTROLYTES USED IN ECM
    CURRENT DENSITY DISTRIBUTION DEPENDS ON THE INTER
    ELECTRODE GAP (IEG)
    ACIDIC ALKALINE NEUTRAL
    SMALLER THE IEG, LARGER CURRENT DENSITY HENCE LARGER
    REACTIONS DURING ECM WITH Fe AS ‘ANODE’ AND NaCl ACQUEOUS SOLUTION AS ‘ELECTROLYE’
    MRR AND VICE VERSA
    2 H2O + 2eˉ → H2 ↑ + 2OHˉˉ
    2Fe – 2eˉ → 2Fe++
    Fe++ + 2OHˉ ˉ → Fe(OH)2
    2Fe + 4 H2O → Fe(OH)3
    Fe(OH)2 , Fe(OH)3 → INSOLUBLE IN WATER
    POSITIVE IONS CONVERT AS HYDROXIDES (FERROUS OR
    FERRIC IN CASE OF IRON AS ANODE / WORK MATERIAL)
    IEG < 1 mm, VOLTAGE  8-20

    NO ELECTROLYTE IS BEING CONSUMED IN THE PROCESS (TOOL HAS


    THEORETICALLY INFINITE TOOL LIFE) 5 6

    DIFFERENT MODES OF ELECTROLYTE FLOW


    MODES OF ELECTROLYTE SUPPLY
     ELECTROLYTE SUPPLY CAN BE IN ONE OF THE THERE
    MODES: OUTWORD MODE OF FLOW. ELECTROLYTE IS
    SUPPLIED THROUGH THE HOLE IN THE TOOL AND EXITS
    THOUGH THE SIDE IEG.

     IN INWARD MODE OF FLOW, ELECTROLYTE ENTERS


    OUTWORD MODE OF FLOW INWARD MODE OF FLOW
    THROUGH THE SIDE IEG AND EXITS THROUGH THE HOLE
    IN THE TOOL.

     SIDE FLOW: ELECTROLYTE ENTERS THROUGH THE SIDE


    IEG FROM ONE SIDE AND EXITS FROM THE OTHER SIDE
    IEG.
    SIDE FLOW

    7 SIDES OF THESE TOOLS ARE COATED WITH INSULATING MATERIALS 8

    2
    9/12/2019

    SCHEMATIC DIAGRAM OF ECD WITH OUTWARD


    MODE OF ELECTROLYTE FLOW

    Coated
    Coated

    STRAY CURRENT
    EFFECT

    9 10

    ELECTROCHEMICAL MACHINING SET-UP ELEMENTS, JOBS & TOOLS


    ELECTROCHEMICAL MACHINING (ECM) SET-UP

    11 COURTESY : METATECH INDUSTRIES PUNE, INDIA 12

    3
    9/12/2019

    ELECTROCHMICAL DISSOLUTION BASED MACHINIG OPERATIONS ELECTROCHMICAL DISSOLUTION BASED MACHINIG OPERATIONS
    ELECTROCHEMICAL BORING ELECTROCHEMICAL DEBURRING

    ECB ( ELECTROCHEMICHAL BORING)

    ECD (ELECTROCHEMICHAL DRILLING)

    ECDe (ELECTROCHEMICAL DEBURRING)

    ECDS (ELECTROCHEMICHAL DIE SINKING) ELECTROCHEMICAL TREPANNING


    ELECTROCHEMICAL GRINDING

    ECG (ELECTROCHEMICHAL GRINDING)

    ECH (ELECTROCHEMICHAL HONING)

    ECM (ELECTROCHEMICHAL MACHINING)

    13 14

    ELECTROCHMICAL DISSOLUTION BASED MACHINIG OPERATIONS APPLICATIONS


    ELECTROCHEMICHAL TURNING ELECTROCHEMICAL WIRE CUTTING (ECWC)  OPERATIONS : TURNING, DEEP HOLE DRILLING, EC
    SAWING, ELECTROCHEMICAL WIRE CUTTING USING TUBE
    AS A WIRE, TREPANNING ETC.

     INDUSTRIES : AERONUTICS, NUCLEAR, SPACE VEHICLES


    AUTOMOBILES, ETC

     PRODUCTS : TURBINE BLADES , CURVILINEAR SLOTS , GEARS REMOVAL


    ELECTROCHEMICAL SAWING (ECS) SHAPED TUBE ELECTROMACHINING (STEM) OF BROKEN HOLE MAKING TO THE WALL INTEGRALLY BLADED NOZZLE
    RING , ETC

     MATERIALS : SPACIALLY DIFFICULT TO MACHINING METALS AND


    ALLOYS FULL CAPABILITIES OF THE PROCESS HAVE NOT BEEN
    EXPLOITED
    15 16

    4
    9/12/2019

    APPLICATIONS APPLICATIONS
    DRILLING HOLES NORMAL TO A WALL SHAPING OF A TURBING BLADE

    17 18

    THINNING AND RADIUSING OF A TURBINE BLADE DEEP HOLE DRILLING

    Work

    19 20

    5
    9/12/2019

    ELECTROCHEMICAL GRINDING

    ELECTROCHEMICAL GRINDING
    (ECG)
     IN ECG WORKPIECE SHOULD BE ELECTRICALLY CONDUCTIVE
     ELECTROLYTE IS USED DURING ECG AND IT IS AFTER PROPER

    FILTR ATION SHOULD BE RECIRCULATED


     FOR ECG GRINDING WHEEL BONDING MATERIAL 

    21 ELECTRICALLY CONDUCTIVE
    22

     GRINDING WHEEL ACTS AS CATHODE AND WORKPIECE AS 3 ZONE OF INTER


    ANODE ELECTRODE GAP
     MATERIAL REMOVAL TEKES PLACE BY 

    (1) ELECTROLYTIC DISSOLUTION

    (2) MECHANICAL ABRASIVE

     MECHANICAL ABRASIVE ACTION 10% &

    ELECTROCHEMACAL DISSOLUTION 90%

     HIGHER WHEEL LIFE COMPARED TO CONVENTIONAL

    GRINDING WHEEL

     COMMON ELECTROLYTES USED DURING ECG : Nacl,

    NaNO3 23 24

    6
    9/12/2019

     ECG FINISHING AREA HAS THREE ZONES


    ZONE 2 
    IN ZONE 1  PURE EC DISSOLUTION TAKES PLACE
    • WHEEL ROTATION HELPS IN DRAWING THE ELECTROLYTE • IN ZONE HIGHER PRESSURE EXISTS DUE TO CONVERGING
    GAP BETWEEN WHEEL & WORKPIECE. IT SUPPRESSES
    • CONTAMINATION OF ZONE 1 TAKES PLACE BY REACTION
    PRODUCTS & GASES FORMATION OF GAS BUBBLES  HIGHER ‘k’ HENCE HIGHER,
    MRR
    • ELECTROLYTE’S ELECTRICAL CONDUCTIVITY ‘K’ CHANGES
    • IN THIS ZONE, ABRASIVE GRAINS ABRADE THE WORKPIECE
    • ELECTROLYTE GETS TRAPPED BETWEEN  ABRASIVE GRIT SURFACE. AS A RESULT THEY REMOVE MATERIAL FROM
    & WORKPIECE TOP SURFACE  IT FORM ELECTROLYTIC WORKPIECE AND OXIDE LAYER FORMED, IF ANY, ON THE

    • SMALL AMOUNT OF MATERIAL IS REMOVE IN THIS WORKPIECE SURFACE


    ZONE  INTERELECTRODE GAP IS COMPARATIVELY • MATERIAL IS REMOVED IN THE FORM OF  CHIPS
    HIGH • OXIDE LAYER  REMOVAL HELPS IN EC DISSOLUTION

    25 26

    ZONE 3 

     IN THIS ZONE, THERE IS NO CONTACT BETWEEN


    ABRASIVE GRAIN AND WORKPIECE SURFACE. WHEEL
    STARTS LIFTING OFF WORK SURFACE.
     HENCE MATERIAL REMOVAL TAKES PLACE BY
    ELECTROCHEMICAL DISSOLUTION

     ELECTROCHEMICAL DISSOLUTION REMOVES


    SCRATCHES & BURRS FORMED IN ZONE 2 ON THE
    WORKPIECE SURFACE.
    Thank You!

    27

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