1. ELECTROCHEMICAL MACHINING

2. Electrochemical Machining - Process
opposite of electro-chemical deposition.
tool and work piece conductive
tool-cathode
workpice- anode
low potential
high current
machining gap to maintained
electrolyte
Electrochemical Machining Process

3. Electrochemical Machining - Process

4. Electrochemical Machining - Process Process Parameters
Power supply
- Type direct current
- voltage to 35 V
- current to 40,000 A
working gap mm to 2 mm
overcut mm to 3 mm
Feed rate to 15 mm/min
Ra to 1.5μm
Electrode material Copper, brass, bronze
Electrolyte
- Material NaCl and NaNo3
- Temperature °c
- flow rate lpm per 100 A current
- pressure to 20 bar
- Dilution g/l to 500 g/l

5. Characteristics of ECM
Tool and work material – electrically conductive
atomic level dissolution
surface finish excellent
almost stress free machined surface
no thermal damage

6. Modelling of MRR in ECM
Materical removal due to atomic dissolution of work material
Electrochemical dissolution is governed by Faraday’s laws
Amount of electrochemical dissolution or deposition proportional to amount of charge
Amount of material deposited or dissolved depends on Electrochemical Equivalence (ECE)
ECE- ratio of atomic weight and valency

7. Modelling of MRR in ECM mαQ m αECE αA/v m α QA/v α ltA/v
m= ltA/Fv F= Faraday’s Constant
= Colomb
MRR = m/tρ = itA/Fvtρ = IA/Fρv

8. EQUIPMENTS FOR ECM FM p M Electrolyte tank w/p Fecl2/Fe(OH)2 tool
Servo system to feeding the tool FM
tool
Insulation on the tool
Power supply
w/p
Fecl2/Fe(OH)2
Electro chemical dissolution p M
Electrolytic filtering unit
Electrolyte tank

9. Applications -ECM die sinking profiling and contouring trepanning
grinding
drilling
micro-machining

10. THANK YOU