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Assignment No 04 Electro Chemical Machining

Electrochemical machining (ECM) is a machining process that uses electrochemical processes to remove material from a conductive workpiece acting as an anode. In ECM, the workpiece and a cathode tool are immersed in an electrolyte and a voltage is applied, causing material to be removed from the workpiece as ions and combine with electrolyte ions. ECM can produce complex shapes and contours with a mirror finish surface due to material removal occurring at the atomic level, and it is used for applications like die sinking, profiling, and machining turbine blades.

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39 views3 pages

Assignment No 04 Electro Chemical Machining

Electrochemical machining (ECM) is a machining process that uses electrochemical processes to remove material from a conductive workpiece acting as an anode. In ECM, the workpiece and a cathode tool are immersed in an electrolyte and a voltage is applied, causing material to be removed from the workpiece as ions and combine with electrolyte ions. ECM can produce complex shapes and contours with a mirror finish surface due to material removal occurring at the atomic level, and it is used for applications like die sinking, profiling, and machining turbine blades.

Uploaded by

Chirag Botkondle
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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Assignment No: 04

Electrochemical Machining (ECM)

Working Principle, Equipment, Advantages and Disadvantages with


Application

Electrochemical machining (ECM) is a machining process in which


electrochemical process is used to remove materials from the workpiece. In the
process, workpiece is taken as anode and tool is taken as cathode. The two
electrodes workpiece and tool is immersed in an electrolyte (such as NaCl). When
the voltage is applied across the two electrodes, the material removal from the
workpiece starts. The workpiece and tool is placed very close to each other without
touching. In ECM the material removal takes place at atomic level so it produces a
mirror finish surface.
 This process is used to machine only conductive materials.
Working Principle

ECM working is opposite to the electrochemical or galvanic coating or deposition


process.
During electrochemical machining process, the reactions take place at the
electrodes i.e. at the anode (workpiece) and cathode (tool) and within the
electrolyte.
Main Equipment of ECM
The ECM system has the following modules
1. Power Supply
2. Electrolyte filtration and delivery system
3. Tool Feed system
4. Working Tank

Schematic Diagram of Electrochemical Drilling Unit

Working Process
 First the workpiece is assembled in the fixture and tool is brought close to the
workpiece. The tool and workpiece is immersed in a suitable electrolyte.
 After that, potential difference is applied across the w/p (anode) and tool (cathode).
The removal of material starts. The material is removed as in the same manner as
we have discussed above in the working principle.
 Tool feed system advances the tool towards the w/p and always keeps a required
gap in between them. The material from the w/p is comes out as positive ions and
combine with the ions present in the electrolyte and precipitates as sludge.
Hydrogen gas is liberated at cathode during the machining process.
 Since the dissociation of the material from the w/p takes place at atomic level, so it
gives excellent surface finish.
 The sludge from the tank is taken out and separated from the electrolyte. The
electrolyte after filtration again transported to the tank for the ECM process.
Application
 The ECM process is used for die sinking operation, profiling and contouring,
drilling, grinding, trepanning and micro machining.
 It is used for machining steam turbine blades within closed limits.
Advantages
 Negligible tool wear.
 Complex and concave curvature parts can be produced easily by the use of convex
and concave tools.
 No forces and residual stress are produced, because there is no direct contact
between tool and workpiece.
 Excellent surface finish is produced.
 Less heat is generated.
Disadvantages
 The risk of corrosion for tool, w/p and equipment increases in the case of saline
and acidic electrolyte.
 Electrochemical machining is capable of machining electrically conductive
materials only.
 High power consumption.
 High initial investment cost.

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