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    Recent Trends in Non-Traditional Machining Processes: Unit - 5

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    DISHA V
    Electrochemical spark machining (ECSM) is a hybrid machining process that combines electrochemical machining and electrodischarge machining. It can machine metals, ceramics, composites, and other difficult-to-machine materials. In ECSM, a voltage is applied between two electrodes submerged in an electrolyte, generating gas bubbles that allow spark discharges to occur. These sparks melt and evaporate small amounts of material from the workpiece, enabling precision microfabrication applications. However, cracking of brittle materials remains a challenge for ECSM to become more practical.

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    Recent Trends in Non-Traditional Machining Processes: Unit - 5

    Uploaded by

    DISHA V
    269 views12 pages
    Electrochemical spark machining (ECSM) is a hybrid machining process that combines electrochemical machining and electrodischarge machining. It can machine metals, ceramics, composites, and other difficult-to-machine materials. In ECSM, a voltage is applied between two electrodes submerged in an electrolyte, generating gas bubbles that allow spark discharges to occur. These sparks melt and evaporate small amounts of material from the workpiece, enabling precision microfabrication applications. However, cracking of brittle materials remains a challenge for ECSM to become more practical.

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    UCMP -UNIT5 (2017 Regulations)

    Original Title

    UCMP-Unit 5

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    Electrochemical spark machining (ECSM) is a hybrid machining process that combines electrochemical machining and electrodischarge machining. It can machine metals, ceramics, composites, and other difficult-to-machine materials. In ECSM, a voltage is applied between two electrodes submerged in an electrolyte, generating gas bubbles that allow spark discharges to occur. These sparks melt and evaporate small amounts of material from the workpiece, enabling precision microfabrication applications. However, cracking of brittle materials remains a challenge for ECSM to become more practical.

    Copyright:

    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    269 views12 pages

    Recent Trends in Non-Traditional Machining Processes: Unit - 5

    Uploaded by

    DISHA V
    Electrochemical spark machining (ECSM) is a hybrid machining process that combines electrochemical machining and electrodischarge machining. It can machine metals, ceramics, composites, and other difficult-to-machine materials. In ECSM, a voltage is applied between two electrodes submerged in an electrolyte, generating gas bubbles that allow spark discharges to occur. These sparks melt and evaporate small amounts of material from the workpiece, enabling precision microfabrication applications. However, cracking of brittle materials remains a challenge for ECSM to become more practical.

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    Download as ppt, pdf, or txt
    of 12

    UNIT – 5

    RECENT TRENDS IN NON-


    TRADITIONAL MACHINING
    PROCESSES
    Electrochemical Sparks Machining
    Process
    • Electro Chemical Spark Machining (ECSM) is an important
    process as it can be applied to metal, ceramics, smart
    material, composites. It can be applied in micro fabrication,
    heat treatment, welding.
    • Advanced ceramics and composites have high potential for
    their application in various field of engineering due to their
    superior properties such as high compressive strength,
    good thermal shock resistance, high wear resistance, high
    hardness, high strength, to weight ratio such improved
    material properties have new challenges in manufacturing.
    • ECSM can become a practical solution for these problems.
    There is need of research for better control, cracking of
    material, deep drilling, tool wear etc.
    • Shaping of the difficult-to-machine non-conductive materials such
    as glass, quartz and ceramic is much difficult and uneconomical by
    existing machining processes.
    • As a result, wide applicabilities of these materials are still limited.
    Even though these materials are highly required in the field of the
    modern industries.
    • To overcome the problem, a new machining method has been
    proposed by researchers by combining the features of electro-
    chemical machining and electro-discharge machining.
    • Such combined machining process is called as electro-chemical
    spark machining process.
    • Such developed machining method becomes an appropriate
    process for machining of non-conductive materials with significant
    improvement in productivity as compared to the electro-discharge
    machining and electro-chemical machining processes.
    Introduction
    • Machining is process of controlled removal of material from
    workpiece to get desired dimensions required for engineering
    component.
    • In traditional machining process tool material should be harder
    than work piece material. This limitation is overcome by many
    advanced manufacturing techniques, like Ultrasonic machining
    (USM), Electrochemical machining (ECM), Electro discharge
    machining (EDM), etc.
    • To get advantage of more than one non-conventional machining
    there immerged concept of Hybrid machining. Electro chemical
    spark machining (ECSM) is also a hybrid machining process which is
    combination of Electrochemical machining (ECM) & Electro
    discharge machining (EDM) which is also known as, Electrochemical
    Engraving, Electrochemical Discharge Machining etc.
    Mechanism of generation of spark in
    electrolyte
    • In ECSM process generally two electrodes are largely different in
    size. Machining may takes place at cathode and anode. The
    electrode which is used as tool is called active electrode and which
    is small in size compared to another electrode, which is called as
    auxiliary electrode.
    • Work piece is kept near to active electrode. Here, voltage applied is
    also large. Due to small shape at active electrode there is large
    current density so large amount of gas is generated there.
    • This gas is nonconductive in nature. So this gas film acts as high
    resistance for electric current so ohmic heating also takes place &
    more number of gas bubbles are generated this gas is passivate
    active electrode.
    • As applied voltage is above break down voltage of gas film there is
    occurrence of spark. Due to this spark gas layer break down takes
    place & again electrochemical reaction starts. This process
    continues. Generally power applied in pulsed form of micro second
    range. This process is shown by operation flow of ECSM
    Material removal mechanism of ECSM
    operation
    • In the ECSM process, the material removal takes place due to the combined
    effects of electrochemical reaction and electrical spark discharge action.
    • Fig.2.3 exhibits the material removal mechanism of ECSM operation.
    Although the tool is touching the surface of the work piece, there are micro
    gaps between the tool and the work piece due to the surface irregularity
    present on both the surfaces of tool and that of the work piece.
    • The electrolyte present in the micro gaps is responsible for the formation of
    gas bubbles and steam generation. A low ionic layer is formed in the micro
    gaps and the surrounding tool surface. When the voltage gradient that is set
    up is sufficient to breakdown the gas bubble layer between the tool and the
    work piece, a conducting path is developed for spark discharge owing to the
    ionization of the gas bubble, which thereby causes the flow of a large
    amount of current.
    • Each electrical discharge causes a stream of electrons to
    move with a very high velocity and acceleration from the
    cathode (or tool) towards the work piece and ultimately
    creates compressive shock waves on the work piece
    surfaces.
    • The phenomenon is completed within a few microseconds
    and the temperature of the spot hit by electrons may rise
    to a very high value. As this high temperature is above the
    melting point of the work piece material, it melts and
    finally evaporates the material.
    • The high pressure of the compressive shock waves creates
    a blast, causing metallic vapors to form wear products in
    the shape of metallic globules, leaving craters in the work
    piece surface
    ADVANTAGES
    • ECSM is very good process that can be applied to metal,
    ceramic, composite and non conductive material.
    • It has less MRR but that is advantage during micromachining.
    • Main obstacle to apply ECSM to miniature component is crack
    near machining.
    • MRR is also dependent on many parameters. To increase
    reproducibility of ECSM, there is need of research to control
    over gas film during dynamic conditions of machining.
    • This process has potential to heat treatment also. Comparing to
    another non conventional process it has less setup cast, so by
    proper modification it can become practical machining process

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