Electrochemical Machining (ECM)

Electrochemical Machining (ECM)
INTRODUCTION:
• Electrochemical machining (ECM) is a machining process in which an electrochemical

process is used to remove materials from the workpiece. The workpiece is taken as an
anode, and the tool is taken as the cathode. The two electrodes workpiece and tool are
immersed in an electrolyte (such as NaCl). When the voltage is applied across the two
electrodes, the material removal from the workpiece starts. The workpiece and tool are
placed very close to each other without touching. In ECM, material removal occurs at the
atomic level to produce a mirror finish surface.
• This process is used to machine only conductive materials.
PRINCIPAL
• Electrochemical machining works on the Faraday law of electrolysis which
state that if two electrodes are placed in a container which is filled with a
conductive liquid or electrolyte and high ampere DC voltage applied across
them, metal can be depleted from the anode (Positive terminal) and plated
on the cathode (Negative terminal). This is the basic principle of
electrochemical machining. In this machining process, the tool is connected
to the negative terminal of the battery (works as a cathode), and the
workpiece is connected to the positive terminal of the battery (works as
anode). They both are placed in an electrolyte solution at a small distance.
When the DC current is supplied to the electrode, metal is removed from
workpiece. This is the basic fundamental of electrochemical machining.
Working Principle
ECM working is opposite to the
electrochemical or galvanic coating or
deposition process.
During the electrochemical machining
process, the reactions take place at the
electrodes i.e. at the anode (workpiece) and
cathode (tool) and within the electrolyte
Let’s take an example of machining low-
carbon steel which is mainly composed of
ferrous alloys (Fe). We generally use a neutral
salt solution of sodium chloride (NaCl) as the
electrolyte to machine ferrous alloys. The
ionic dissociation of NaCl and water takes
place in the electrolyte as shown below.
As the potential difference is applied across the electrode, the movement of ions starts
in between the tool and w/p. The positive ions move toward the tool (cathode) and the
negative ions move toward the workpiece.
At the cathode, the hydrogen ions take electrons and get converted into hydrogen gas.
In the same way the iron atoms comes out from the anode (w/p) as Fe++ ions
Within the Electrolyte, the sodium ions combines with Hydroxyl ions and form sodium
hydroxide and ferrous ion combine with Chloride ions and forms ferrous chloride. Also
iron ions combine with hydroxyl ions and form Iron hydroxide..
• In the electrolyte, the FeCl2 and Fe(OH)2 are produced and get
precipitated in the form of sludge and settle down. In this way, the
material is removed from the workpiece as sludge.
• The various reactions taking place in the Electrochemical machining
process are in the figure given below.
The ECM system has the following modules or Main
Equipment of ECM
1.Power Supply
2.Electrolyte filtration and delivery system
3.Tool Feed system
4.Working Tank
Working of Electrochemical Machining
• First, the workpiece is assembled in the fixture and the tool is brought close to the workpiece. The
tool and workpiece is immersed in a suitable electrolyte.
• After that, a potential difference is applied across the w/p (anode) and tool (cathode). The removal
of material starts. The material is removed in the same manner as we have discussed above in the
working principle.
• Tool feed system advances the tool towards the w/p and always keeps a required gap in between
them. The material from the w/p comes out as positive ions and combine with the ions present in
the electrolyte and precipitates as sludge. Hydrogen gas is liberated at the cathode during the
machining process.
• Since the dissociation of the material from the w/p takes place at atomic level, so it gives an
excellent surface finish.
• The sludge from the tank is taken out and separated from the electrolyte. The electrolyte after
filtration again transported to the tank for the ECM process.
Application
• The ECM process is used for die sinking operation, profiling and contouring, drilling,
grinding, trepanning and micro machining.
• It is used for machining steam turbine blades within closed limits.

Electrochemical Machining (ECM)

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Electrochemical Machining (ECM)

• Electrochemical machining (ECM) is a machining process in which an electrochemical

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