Electrochemical Machining (ECM) and Grinding
Electrochemical Machining (ECM) and Grinding
Electrochemical Machining (ECM) and Grinding
Machining (ECM)
and Grinding
Electrochemical
Machining
This is washed just before they have a chance to plate on the tool
( cathode)
Electrochemical
Machining
Normally, the gap between the tool and the work-piece is of the
order of 0.25 mm to 1 mm.
Process capabilities
Electrochemical
Machining
Electrochemical
Machining
Operating Principle
Operating Principle
Main Subsystems
ECM Components
(Power)
ECM Components
(electrolyte circulation
system)
11
ECM Components
(control system)
12
ECM Components
(Machine)
Advantages
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.
16
Applications
Economics
Products
19
Safety Considerations
Safety Consideration
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.
22
Electrolyte
The
Electrolyte
24
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
25
Electrochemical
Grinding
26
Electrochemical
Grinding
27
Advantages of ECG
Disadvantages