Electro chemical machining (ECM) is a non-traditional machining process that removes metal by electrochemical dissolution. It can machine very hard materials and intricate geometries by controlling the electric current between the workpiece and cathode tool through an electrolyte. In ECM, metal removal occurs at the anode workpiece due to electrolysis, while the cathode tool remains unaltered. Key factors like voltage, current density, electrolyte type and flow rate, and gap width determine the ECM process.
Electro chemical machining (ECM) is a non-traditional machining process that removes metal by electrochemical dissolution. It can machine very hard materials and intricate geometries by controlling the electric current between the workpiece and cathode tool through an electrolyte. In ECM, metal removal occurs at the anode workpiece due to electrolysis, while the cathode tool remains unaltered. Key factors like voltage, current density, electrolyte type and flow rate, and gap width determine the ECM process.
Electro chemical machining (ECM) is a non-traditional machining process that removes metal by electrochemical dissolution. It can machine very hard materials and intricate geometries by controlling the electric current between the workpiece and cathode tool through an electrolyte. In ECM, metal removal occurs at the anode workpiece due to electrolysis, while the cathode tool remains unaltered. Key factors like voltage, current density, electrolyte type and flow rate, and gap width determine the ECM process.
Electro chemical machining (ECM) is a non-traditional machining process that removes metal by electrochemical dissolution. It can machine very hard materials and intricate geometries by controlling the electric current between the workpiece and cathode tool through an electrolyte. In ECM, metal removal occurs at the anode workpiece due to electrolysis, while the cathode tool remains unaltered. Key factors like voltage, current density, electrolyte type and flow rate, and gap width determine the ECM process.
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ELECTRO CHEMICAL MACHINING
Non-traditional machining process
Energy Domain – Electro-chemical category.
Metal removal by electrochemical process.
For machining extremely hard materials or materials
that are difficult to machine using conventional methods. ELECTRO CHEMICAL MACHINING
Limited to electrically conductive materials.
For machining or cutting the intricate contours or
cavities in hard materials such as titanium, Hastelloy, Kovar, Inconel, Carbide etc.
External as well as internal geometries can be
machined. ECM is characterized as the opposite of electrochemical or galvanic coating or deposition process. It is based on Faraday’s laws of electrolysis (electroplating).
Similar to EDM. However, in ECM there is no tool wear.
ECM Fundamentals Electrolysis of a copper sulphate solution As per polarity, the chemical reactions occurring at the anode and cathode are called anodic and cathodic reactions respectively. Due
At the anode, the metal dissolves electrochemically.
The rate of dissolution depends upon:
The ionic charge
Atomic weight The current and The time of current passage. The rate of dissolution is not influenced by the hardness of the work piece material or any other metal characteristics.
At the cathode, only the hydrogen gas is evolved.
The electrode shape remains unaltered during the
electrolysis process. This is the most relevant feature of ECM being used as a metal shaping process. Mechanism of Material Removal in ECM The work piece and tool are the anode and cathode respectively.
A suitable electrolyte, for example an aqueous sodium
chloride (table salt) solution is commonly chosen.
In the electrolytic cell a constant potential difference,
usually of about 10 V is applied across them.
The rate at which metal is then removed from the
anode is approximately in inverse proportion to the distance between the electrodes. As the machining proceeds there is a simultaneous movement of the cathode towards the anode.
The width of the gap along the electrode length will
gradually tend towards a steady-state value.
Under such conditions, a shape which is roughly
complementary to that of the cathode will be reproduced on the anode.
In-order to remove the products of machining, the
electrolyte is pumped through the gap between the two electrodes. Power System In the ECM setup, as the gap between tool and work piece is small, a low and constant voltage of around 10 V is applied across the electric circuit. The current density is however high.
Electrolyte Filtration and Delivery System
The electrolyte system consists of the electrolyte
storage tank, fairly strong pump, filter, sludge removal system and treatment units. The electrolyte chosen is such that the shape of cathode is not changed during electrolysis.
To remove the products of machining and to reduce
the undesirable effects which may arise with the gases generated at the cathode and electrical heating, the electrolyte is pumped at a rate of 2 to 30 m/s, through the gap between the electrodes. Tool Feed system In the ECM setup, a constant gap between tool and work piece is to be maintained.
Tool Material Properties
Should be a good conductor of electricity.
Should be rigid enough to take up load and the
fluid pressure. Easily formable and machinable to the desired shape. Tool Material
Common materials:
Copper, Brass, Titanium, Copper-Tungsten and
Stainless steels.
Other materials:
Aluminium, graphite, bronze, platinum, and
tungsten carbide. ECM Process Parameters
Power Supply: It’s Type, Voltage, Current and Current