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Practical Applications & Considerations of

Electro-Chemical Deburring

Rich Taufer
Senior Sales Engineer
Vectron
Elyria, Ohio

Deburring is an ever increasing and important consideration relating to metal cutting and
metal removal operations. The Electro-Chemical Deburring process has proven to be an
excellent process in accomplishing reliable and consistent burr removal on a wide variety of
applications. Electro-Chemical deburring can be used on all electrically conductive engineering
materials. The process can easily be adapted to deburring simple, as well as complex and
delicate close-tolerance parts. Described are practical applications of the Electro-Chemical
Deburring process, including tooling considerations, benefits and limitations.

For more information, contact:

Rich Taufer
Vectron
201 Perry Court
Elyria, Ohio 44035
Phone - (440) 323-3369
Fax - (440) 323-3139
E-mail: rt@vectron.cc

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 Introduction

As mechanical, electrical, and fluid power systems become more technologically advanced,
the potential problems resulting from system contamination become an ever-increasing concern.
As individual mechanical components of such systems become more precise with tighter
manufacturing tolerances, they become more sensitive to burrs that can adversely affect form, fit
and function.

Today there are dozens of deburring alternatives available that range from using
sophisticated hand deburring tools, to fast and efficient mass finishing systems. Electro-
Chemical Deburring (ECD) falls near the “fast and efficient mass finishing” end of the spectrum
of deburring processes. ECD has been used as a production deburring process for many years,
and is used routinely by nearly every metal cutting industry. Figure 1 shows a variety of
workpieces deburred using the ECD process.

Figure 1. Assorted workpieces deburred using ECD.

ECD Basics

ECD, as the name implies, uses electrical energy to accomplish the work of deburring. The
action of the process is very localized and the affected area can be accurately sized and precisely

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 located. Using carefully designed fixtures, the process easily removes the burr while leaving all
other areas of the workpiece virtually unaffected. Aside from hand deburring, the ECD process
is the only deburring process that can pinpoint selected locations to deburr. Because the process
operates at near room temperatures, there is no danger of changes in the characteristics of the
workpiece material. The fixture clamping forces are relatively small and workpiece distortion is
rarely a concern.

The ECD process is accomplished by placing a metallic electrode close to the burr. The
electrode is shaped to conform to the perimeter of the area where the burr is attached. With the
electrode in place, an electrolyte solution is flowed through a small gap between the workpiece
and the electrode. Then, a low-voltage/high- current is passed through the electrolyte
solution between the workpiece and the electrode. This action results in what might be called a
reverse plating operation, which causes the burr exposed to the electrode to essentially be
dissolved. Figure 2 is a schematic diagram of the basics of the ECD process.

DC Power Supply

Electrode

Contact Bar
Electrolyte Flow

Workpiece

Locator

Fixture Base

Figure 2. Schematic diagram of ECD basics.

A fixture is used to locate the workpiece so that the burrs are carefully positioned and
oriented relative to the electrode. Most applications of the ECD process use stationary fixtures
with permanently mounted locators and electrodes. Other applications employ stationary
fixtures with moveable locators and/or electrodes. The moveable locators and/or electrodes
permit access to burrs in difficult locations that cannot be reached by simply slipping the

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 workpiece on and off a fixed locator/electrode. Workpieces processed on stationary fixtures may
range in size from the size of a pencil eraser to many pounds.

As opposed to the fixed locators/electrodes, the ECD process can consist of a

locator/electrode combination that is held in the hand and manually placed at the area to be
deburred. The workpiece could be small and held in the hand and deburred with the hand held
locator/electrode. Furthermore, the workpiece could be unlimited in size, or even immovable for
that matter, and the hand held locator/electrode moved to any burr location on the workpiece for
processing.

Burrs located on the external surfaces of a workpiece are often readily accessible and can be
economically removed by mass finishing processes or “quick” hand deburr methods. For this
reason, most applications of the ECD process are for deburring internal areas that do not lend
themselves to mass finishing processes. However, if a workpiece has delicate or critical features
that might be damaged by mass finishing, such a workpiece can be ECD’d on the external
surfaces as easily as it is deburred internally. Figure 3 shows examples of external deburring
applications that are not good candidates for mass finishing because of the external threads.

Figure 3. Good applications for ECD on external burrs.

The primary components of the ECD process consists of the workpiece; fixtures with
locators, electrodes and clamps; electrolyte and electrolyte plumbing, including metering valves,
coolers and filters; the electrics, including power supply, timers, and voltage controls; and the
post cleaning processes.

In addition to the fixtures, locators and electrodes, the variable elements of the process are:
cycle time, electrolyte, electrolyte flow, electrolyte concentration, electrolyte temperature, and
voltage. These elements can be changed individually or in various combinations to cause subtle
to dramatic differences in the ECD results.

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 The ECD process is often confused with EDM and Electropolishing, but they are all quite
different. Electropolishing employs a low-voltage/high-current flow to remove material on all
exposed surfaces of a workpiece immersed into an acidic electrolyte solution. The EDM process
employs a high-voltage/low-current flow that arcs through a dielectric liquid to accomplish the
metal removal process.

Fixtures

ECD fixtures are usually composed of a two-piece fixture base, nonconductive locators,
metallic electrodes, metallic contact bars, electrical terminals, and fittings to attach electrolyte
piping. The two-piece fixture base is comprised of a metallic sub-plate and a nonconductive top-
plate. Figure 4 shows a basic ECD fixture and a more complex fixture.

Mask
Electrode

Locator

Figure 4. Basic (left) and complex (right) ECD fixtures.

The sub-plate provides for the rigid mounting of the electrodes and for making electrical
continuity with the electrodes. The sub-plate is plumbed and ported to direct the electrolyte flow
into and/or around the locators and/or the electrodes. The sub-plate can be made from most any
conductive material.

The primary function of the top-plate is to firmly connect and clamp the locators to the sub-
plate. It also positions the locators relative to the electrodes, which in turn locates the workpiece
to the electrodes. Other locating elements may be attached to the top-plate to aid in locating the
workpiece. The top-plate may be ported to assist in directing the electrolyte flow. The top-plate
can be made from many nonconductive plastic materials.

The contact bar provides electrical continuity with the workpiece, and transmits the clamping
forces to the workpiece to insure the workpiece remains stationary during the ECD cycle.
Contact bars are made of conductive materials and are generally attached to the clamping
mechanism of the ECD machine.

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 Locators

Locators perform several functions. They are used to locate the workpiece relative to the
electrode, which in turn locates the electrode relative to the burr. The locator serves as an
electrical insulator between the workpiece and the electrode, and provides plumbing circuits to
direct the electrolyte flow. Locators can be made of many nonconductive plastic materials.

The condition of the locators must be carefully monitored during production runs. Cracks in
and/or scratches on the locators can allow current or electrolyte leakage that can cause ECD
action in unwanted areas of the workpiece.

Electrodes

The design, shape, and location of the electrode are critical to achieving successful ECD
results. The electrode can be manufactured from a variety of conductive materials. They can be
manufactured from solid bar stock, bent into shapes from wire, or fabricated into shapes from
thin sheet stock. Because of the limitless variations of burr locations, burr size, workpiece
tolerances, etc., the electrodes require ingenuity in design and manufacturing to achieve a final
shape that insures the desired results. The electrical conductivity of the electrode material can
influence the rate of deburring and the overall power consumption of the process.

A critical requirement of the ECD process is insuring that the electrode never makes contact
with the workpiece to create a direct short. A short may occur when a workpiece is not made to
print specifications. For example, the diameter of a hole may be too small or not drilled deep
enough. In addition, electrodes may become bent or chips may get into the gap.

A short causes a current spike that can cause an arc that damages the workpiece and the
electrode. Damage to the workpiece is usually the result of excessive and/or erratic material
being removed at a critical location, and which could necessitate scrapping the workpiece. In
this case, the fixture can be repaired, and only a single workpiece is lost.

A subtle situation may occur when an electrode is unknowingly damaged by an arc that
leaves some workpiece material “welded” onto the electrode. Furthermore, arcing can cause pits
or voids in the electrode. Any of these conditions may cause erratic results that may go
undetected until many workpieces have been processed, and possibly scrapped.

The ECD machine should include an option to detect a short and shut the system down when
one occurs. It is important to carefully inspect the electrodes and locators after a short, or
suspected short has occurred.

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 Masking

Masking consists of covering, insulating or otherwise shielding a portion of the electrode in

order to protect specific areas of the workpiece from the ECD action, while still allowing the
process to do its work on the burr. Masking is an important element in the process of
configuring the electrode to match the shape of the burr location.

Masking may be accomplished by placing the electrode inside of the locator, and permitting
only a small section of the electrode to be exposed to the workpiece. A close fit between the
workpiece and the locator will restrict electrolyte flow and mask the ECD action at the area of
close fit. Effective masking can also be accomplished with the use of O-Rings, rubber bands,
tape, glue, and epoxy materials. The ECD action on the workpiece is inversely proportional to
the square of the distance to the electrode. Therefore, distance can serve as a form of masking,
and some workpiece areas that are not near the electrode may not need to be masked.

Pattern Shapes

As previously mentioned, the shape of the electrode can be made to match the shape of the
area to be deburred. The shape of the electrode can be limitless. Figure 5 shows a Control Lever
with kidney shaped slots that are easily ECD’d using irregular shaped electrodes.

Figure 5. Irregular shaped ECD pattern.

When designing the ECD pattern, it is important to consider how close the pattern should
match the burr area. Generally, the pattern should be larger than the burr area in order to insure
thorough deburring and that the desired edge condition is achieved. Consideration must be given
to the allowable tolerances on the workpiece, clearances between the workpiece and the
locator/electrode, and fixture tolerances. These tolerances can stack-up and permit the ECD

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 pattern to shift relative to the burr area, and when this happens, a portion of the burr can be
“missed” by the process. Consequently, the ECD pattern must be sufficiently large to
accommodate the allowable variations and still ensure proper burr removal and final edge
condition.

The Flange in Figure 6 shows a pattern that is elongated horizontally. The crosshole is
visually located relative to the electrode and the elongated pattern allows for slight errors in
alignment. Because the vertical location of the hole is controlled by the fixture components, the
vertical spread of the pattern can be much less.

Figure 6. Flange with elongated ECD pattern.

It is important to evaluate whether each burr location on a workpiece should be ECD’d

individually, using multiple electrodes to produce individual spots, or if several burr locations
could be ECD’d at one time, using one large electrode to produce a band. The Sleeve shown in
Figure 7 was ECD’d using 6 electrodes to produce 6 separate bands for deburring the ID. The
same Sleeve, shown in Figure 8 was processed using 144 individual electrodes to produce 144
separate spots for deburring the ID. Loading the workpiece onto the fixture in Figure 7 is much
quicker because the Sleeve does not have to be accurately positioned to insure the electrodes are
aligned with the holes. In addition, the fixture in Figure 7 is more robust and requires less
maintenance.

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 ECD Band

Figure 7. ID deburred with 6 electrodes. Figure 8. ID deburred with 144 electrodes.

The form, fit and function of the workpiece may dictate the use of the spot approach vs. the
band approach. This could happen where the slight amount of material removed between
adjacent holes could act as a fluid leak path between the holes. For any given workpiece, the
individual spot approach uses less power and introduces less contamination into the electrolyte
system. However, the design and construction of fixtures utilizing the individual spots is
considerably more complex than fixtures utilizing the band pattern. If the band pattern can be
used, the cycle time can often be improved because less attention is required in locating the
workpiece on the fixture.

Electrolyte

Numerous chemicals, or chemical combinations, can be mixed with water to produce an

electrolyte solution. The most common solutions are Sodium Chloride or Sodium Nitrate, with
Sodium Chloride being the most popular. The parameters of the electrolyte that are controlled
are: chemical analysis, concentration, flow rate, temperature, and cleanliness.

The role of the electrolyte solution is much more than to simply provide a path for current
flow. The workpiece is not merely immersed into the electrolyte, but the electrolyte is carefully
flowed between and around the burr and the electrode in a prescribed manner in order to
accomplish specific results. The flow is a function of the fixture and its integral electrolyte
plumbing passages. In addition, as the burr is being “deplated,” the material that is being
removed must be moved away from the electrode, by the electrolyte stream, so that it is not
plated onto the electrode.

As the burr is being removed, it is possible that a section of the burr could be dissolved
which might allow a piece of the burr to become detached and carried downstream with the
electrolyte flow. If this happens, and the gap is located downstream, a piece of the burr could
become lodged between the workpiece and the electrode and create a short. For this reason,
always design the electrolyte flow to carry these pieces away from the gap.

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 The electrolyte flow can be plumbed through the locator and/or electrode and directed toward
the workpiece, or, the flow can be plumbed through the workpiece and directed toward the
locator and/or electrode. These options will produce different results. The choice of the
direction of flow may be dictated by the constraints of the workpiece size, shape, etc. In
addition, the electrolyte can be plumbed and directed to create a flow that is laminar, turbulent,
or spiral in motion. These options will produce different results.

The material that is being removed from the burrs, and other areas of the pattern, is
introduced into the electrolyte system, and is referred to as “sludge.” To keep the electrolyte
fresh, and extend its life, a filtering process is used to remove the sludge. Depending on the
material of the workpiece, the sludge may contain heavy metals such as chrome, nickel, etc.
Because of EPA constraints, these materials can be difficult and expensive to dispose of.

Electrical

The ECD power supply provides a low-voltage/high-current DC output for the process. The
output can be a constant voltage for a steady current flow, or can be pulsed for a fluctuating
current flow. As the burr is removed, the distance between the electrode and the workpiece
increases which results in a progressively lower current flow. Some systems can compensate for
this, which results in more uniform deburring, and quicker cycle time. These options can
produce different results for any given material.

“Current density” is a term frequently used in discussions of Electro-Chemical Deburring. It

is the ratio of current to unit area. Current, or current density, is a function of the length of the
burr edge being deburred, or the size of the ECD pattern. The burr removal rate is a function of
the voltage applied.

Cycle Time

The cycle time for processing a given workpiece is governed by the amount of material to be
removed, which is determined by the length and thickness of the burr. The variables influencing
the actual cycle time are: voltage, electrolyte temperature and gap width. Generally, increasing
the voltage, warming the electrolyte, narrowing the gap, or a combination of these will reduce
the deburring cycle time.

Qualifying

As mentioned earlier, the presence of loose chips, lodged chips, or large burrs can result in a
short circuit that will usually damage the electrode, workpiece, or both. Because of the potential
for arcing and damage, the workpiece may require “qualifying” before ECD processing.

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 Qualifying is the process of removing chips, hanging burrs or excessively large burrs to provide
unrestricted access for the locator/electrode. A hanging burr might be similar to an attached drill
cap; sometimes called a toilet seat burr or hubcap burr. Large burrs are long or tall, and are
created by dull tools and/or high feed rates. In either case, these conditions may cause arcing
and must be eliminated before ECD processing.

Figure 9 illustrates a Hub that requires qualifying for ECD. The locator/electrode must enter
into the crosshole shown, and obviously would become entangled with the large and loose burrs.
Qualifying may be accomplished by reaming, drilling, brushing, bead blasting, mass finishing,
Thermal Deburring or hand methods.

Figure 9. Hub requires qualifying before ECD.

Degreasing

The cleanliness of the workpiece before the ECD processing is an important consideration.
As already discussed, chips and other forms of metallic contamination will usually result in a
short. Contamination from nonmetallic particles can restrict electrolyte flow. Additionally,
many cutting fluids, preservatives, rust inhibitors, and chemicals are dielectrics. Even small
traces of these materials can appear as random “masks” to the process and cause erratic results.
This is particularly true on workpieces with close tolerances, and where uniform results are
important. All of these contaminants will deteriorate the condition of the electrolyte solution and
shorten its life.

Post-ECD Cleaning

Special cleaning of the workpiece is usually required following the ECD process. The area
where the burr is removed, and immediately adjacent to it, is often discolored and darker in
appearance. The deposit of hydroxides or oxides, roughness of the surface, or a combination of
these are thought to be causes of the discoloration. The discoloration is referred to as “smut” and
is generally removed by mechanical means or chemical cleaning. Simply washing the workpiece

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 will not remove the smut. Sometimes the smut can remain on the workpiece, and simply rinsing
off the electrolyte solution in order to avoid corrosion, may be all that is necessary. Figure 10
shows a Nut with smut before and after cleaning.

Figure 10. Nut with smut before (left) and after (right) cleaning.

Hand brushing, power brushing, buffing, polishing, bead blasting, etc can mechanically
remove smut. Smut can be removed chemically by a number of cleaning processes. Different
workpiece materials, as well as different alloys, usually require different chemical cleaning
processes.

If the workpiece is heat treated, plated, passivated, or painted following the ECD process,
these processes can often remove the smut and eliminate the need for post-ECD cleaning. In
these cases, a quick rinse to remove the electrolyte solution, and the application of a rust
inhibitor in the case of steel workpieces, may be all that is necessary to achieve an acceptable
condition.

Workpiece

Virtually any metallic engineering material can be deburred using the ECD process, however,
some materials respond better than others. The best candidates are aluminum and stainless steel
alloys. These materials usually exhibit smooth, consistent, and bright edge breaks. Titanium is
marginally acceptable for the process.

ECD is routinely used to deburr workpieces made by every forming and/or machining
process. Workpieces made from forgings, die castings, sand castings, extrusions, powdered
metal, investment castings, heading, drawing, etc. lend themselves to ECD processing.
Workpieces made by turning, milling, drilling, stamping, piercing, broaching, shaping, etc. are
routinely ECD’d.

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 Workpiece Design

The design of a workpiece can have a significant impact on the ease and success of achieving
the expected deburring requirements. Creativity in the initial design of the workpiece can even
eliminate the need to remove some burrs. For example, a strategically placed relief, undercut,
chamfer, etc. can provide a nonfunctional, out of the way, place for a burr to “hide.” Doing this
can often simplify the ECD processing.

Manufacturing Processes

The sequence of the manufacturing processes determines where the burr will end up and
what direction it is pointing. The order of the operations can be designed to insure that the burr
ends up in a location where it is more readily accessible for deburring. This can make it easier to
qualify, permit quicker deburring cycles, and/or allow for less critical deburring requirements.

The Swivel Body shown in Figure 11 illustrates the impact the sequence of operations can
have on the choices for deburring. The bore shown is a critical, close tolerance bore. The
critical bore on the Body on the left was machined after a threaded crosshole was machined.
This sequence pushed the burr into the threaded hole, which allows a locator/electrode and mask
to enter the critical bore to precisely ECD only the intersection. The Body on the right was
threaded after the critical bore was finished, leaving burrs protruding into the bore. This
prohibits a locator/electrode and mask from entering the critical bore without being qualified.
However, the locator/electrode could be place into the threaded hole and successfully deburr the
intersection, but this would allow electrolyte to flow onto the surface of the critical bore with
possible adverse affects.

Figure 11. Sequence of machining. Figure 12. Sequence of ECD’ing.

Figure 12 shows a small diameter crosshole breaking into the large threaded diameter. In this
case, it would not be practical to place a thin and fragile locator/electrode into the small diameter
crosshole to accomplish the deburring. If the small hole was drilled first, then the thread was
machined, the burrs would be pushed into the small hole. This would allow a large, robust
locator/electrode to be placed into the threaded hole without qualify first. If the crosshole were
drilled last, the thread would probably have to be qualified before performing the ECD process.

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 Burrs

“How much burr can be removed with the ECD process?” is a frequently asked question.
The answer is, given sufficient cycle time and current flow; a burr of any size can be removed.
However, this is not a practical solution to burr removal.

A universally accepted definition of a burr does not exist, and some aspects of burrs and
deburring continue to remain vague and nebulous. Consequently, it is important for engineering,
production, and quality personnel to have a good understanding of burrs for the ECD process to
be successful. Some industries, professional societies and companies have developed their own
definitions and standards that are very helpful.

Usually, close design tolerances dictate using carefully controlled machining operations,
better tooling, better tool maintenance, etc. in order to maintain the required tolerances. This
usually results in smaller, thinner, and more manageable burrs. The better burr condition allows
for a smaller and more accurately placed ECD pattern, along with smaller gaps between the
workpiece and electrode. This improves the overall success of ECD applications.

Safety

The ECD process is generally considered very safe. Other than the normal cautions
exercised when working around 220-volt appliances, or machinery and water, the relatively low
voltage employed by the actual deburring action poses little potential for electrical shock. The
clamping forces of the contact bars are generally low and can rarely do serious harm if a careless
mistake occurs.

The most common electrolyte, Sodium Chloride, requires no more caution than handling
table salt in the kitchen. Sodium Nitrate should be given special attention because it is
flammable under certain conditions. In solution, Sodium Nitrate is quite safe. However, when it
becomes dried onto porous materials, like paper or cloth, it can become flammable, and should
be handled with care and disposed of properly.

Benefits

The results of the ECD process are extremely uniform and predictable. The process gets into
inaccessible areas that are not possible for mechanical deburring processes. Fragile workpieces
are natural candidates for the ECD process.

The initial costs to purchase the ECD process, and tool-up, are considered reasonable. The
consumable material for the ECD process, the electrolyte, is considered very inexpensive

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 compared to medias used in other processes. The ECD electrolyte is easily removed from the
workpiece, and there is no gritty residue to clean or stuck media to dislodge.

ECD is quicker than hand deburring, particularly when several areas of a workpiece are
deburred. An ECD operator can be trained to set-up and run several part numbers quicker than a
person can be trained with the requisite “craftsmanship” skills to competently hand deburr a
single part number. The results of the ECD process are uniform and reliable; if the part goes on
the fixture, the process does not forget to do a hole. Often the ECD pattern can be a “signature”
to visually and quickly determine if a workpiece is deburred.

Limitations

Aside from the marginal success with Titanium, the major limitation is that plastics and other
nonconductive materials cannot be deburred using the ECD process. Sometimes, considerable
experimentation is necessary to optimize the electrolyte options for any given material. This can
be particularly challenging when several materials are processed on the same machine.

Summary

The ECD process is widely accepted and successfully used in many industries including:
aircraft, automotive, aerospace, nuclear, medical, semiconductor, fluid power, screw machine,
Swiss machining, CNC machining, job shops, etc.

The days are long gone when deburring operations were performed by someone tucked away
in a dim corner of a manufacturing plant and using a specially shaped blade of a pocket knife, or
a sharpened hook on the end of a piece of welding rod. This might work for a few prototype
samples, but as manufacturing engineers see the potential for increasing backlogs and larger
scrap barrels in the deburring departments, the ECD process should not be ignored.

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