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    Electrochemical Grinding (ECG) : Dr. Sanjeev Sharma Professor, Deptt. of Mech. Engg. CEC, Landran

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    Abhishek Kumar
    Electrochemical grinding (ECG) is a grinding process where material is removed from the workpiece through both mechanical abrasion (10%) and electrochemical dissolution (90%) with an electrolyte. It produces less defects than conventional grinding such as burrs, heat affected zones, and residual stresses. ECG uses an electrically conductive grinding wheel and workpiece with an electrolyte flowing between them. Common electrolytes used are sodium chloride and sodium nitrate.

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    Electrochemical Grinding (ECG) : Dr. Sanjeev Sharma Professor, Deptt. of Mech. Engg. CEC, Landran

    Uploaded by

    Abhishek Kumar
    325 views14 pages
    Electrochemical grinding (ECG) is a grinding process where material is removed from the workpiece through both mechanical abrasion (10%) and electrochemical dissolution (90%) with an electrolyte. It produces less defects than conventional grinding such as burrs, heat affected zones, and residual stresses. ECG uses an electrically conductive grinding wheel and workpiece with an electrolyte flowing between them. Common electrolytes used are sodium chloride and sodium nitrate.

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    Electrochemical grinding (ECG) is a grinding process where material is removed from the workpiece through both mechanical abrasion (10%) and electrochemical dissolution (90%) with an electrolyte. It produces less defects than conventional grinding such as burrs, heat affected zones, and residual stresses. ECG uses an electrically conductive grinding wheel and workpiece with an electrolyte flowing between them. Common electrolytes used are sodium chloride and sodium nitrate.

    Copyright:

    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    325 views14 pages

    Electrochemical Grinding (ECG) : Dr. Sanjeev Sharma Professor, Deptt. of Mech. Engg. CEC, Landran

    Uploaded by

    Abhishek Kumar
    Electrochemical grinding (ECG) is a grinding process where material is removed from the workpiece through both mechanical abrasion (10%) and electrochemical dissolution (90%) with an electrolyte. It produces less defects than conventional grinding such as burrs, heat affected zones, and residual stresses. ECG uses an electrically conductive grinding wheel and workpiece with an electrolyte flowing between them. Common electrolytes used are sodium chloride and sodium nitrate.

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    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd
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    ELECTROCHEMICAL

    GRINDING
    (ECG)

    Dr. Sanjeev Sharma


    Professor, Deptt. of Mech. Engg.
    CEC, Landran
    Grinding
    Removal of the metal from the work piece using tool made
    from abrasive particles of irregular geometry.
    Conventional Grinding

    Good surface finish & tolerances .

    Presence of burrs, HAZ, & thermal


    residual stresses .

    100 % removal by abrasive action


    Electrochemical grinding

    W/p electrically conductive


    Electrolyte re-circulated .
    Grinding wheel bonding material
    →electrically conductive
    Mechanical abrasive action →10%
    Electrochemical dissolution → 90 %
    Long wheel life
    Common electrolytes: NaCl & NaNo3)
    Electrochemical grinding

    Conventional grinding produces components


    with good surface finish and dimensional
    tolerances but such components are also
    associated with burrs, comparatively large heat
    affected zone (HAZ), and thermal residual
    stresses. These defects are not found in
    electrochemically ground work pieces (anodes).

    During electrochemical grinding (ECG), material


    is removed by mechanical abrasive action
    (about 10%) and by electrochemical dissolution
    (about 90%) of anodic work piece.
    Electrochemical grinding

    A combination of ECM and abrasive


    grinding in which most of the metal is
    removed by electrolytic action.

    It is used with hard carbides or difficult-to-


    grind alloys where wheel wear or surface
    damage must be minimized.
    Electrochemical grinding

    Electrochemical grinding (ECG)


    Electrochemical grinding

    Schematic diagram of a typical ECG system.


    Electrochemical grinding
    Electrolyte is re-circulated in ECG, hence, an effective
    and efficient electrolyte supply and filtration system is
    needed. The commonly used electrolytes are sodium
    chloride (NaCl) and sodium nitrate (Na-N03).

    In ECG, there is a grinding wheel (cathode) similar to a


    conventional grinding wheel except that the bonding
    material is electrically conductive.

    Electrolyte is supplied through inter electrode gap (lEG)


    between the wheel and the work piece.

    Life of the ECG wheel is about ten times more than that
    of the conventional grinding wheel.
    ECG Operations

    Electrochemical cylindrical grinding,

    Electrochemical form grinding

    Electrochemical surface grinding

    Electrochemical face grinding

    Electrochemical internal grinding.


    Advantages
    Increased material removal rates.

    Reduced cost of grinding. Despite the fact that the machine


    required is comparatively expensive, the increased rate of
    metal removal and the reduced consumption of abrasive material
    more than compensate for the extra capital cost.

    Reduced heating of work piece; and therefore, less risk of thermal


    damage.

    Absence burrs on the finished surface.

    Improved surface with no grinding scratches.

    Reduced pressure of work against the wheel.


    Applications
    Economical in grinding carbide cutting tools.

    EC ground cemented carbide w/p →no damage to microstructure &


    no micro cracks.

    No effect on gear hardness.

    Burr-free sharpening.

    Super alloy, turbine blades & honeycomb metals.

    Sharpening of cemented carbide tools.


    Applications
    (i) Carbide Cutting Tools
    The process of ECG is most extensively
    used for the grinding of carbide cutting
    tools.

    In comparison with conventional grinding,


    ECG provides savings of about 75 % in
    wheel cost and about 50% in labour costs
    in grinding tungsten carbide.
    Applications
    (ii) Fragile or Very Hard and Tough Materials
    ECG is-particularly useful for grinding
    fragile parts such as honeycomb, thin
    walled tubes and skins etc.

    Further, high production rates can be


    achieved when grinding hard, tough, work
    hardenable or heat-sensitive materials.

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