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ECG 1st Lecture

Electrochemical grinding (ECG) is a process that combines electrolytic activity with physical material removal using electrically charged abrasive wheels. It produces precise, burr-free cuts without heat or mechanical stresses. ECG removes most material electrolytically, with some removal by the abrasive wheel. It can machine hard materials like tungsten carbide and achieve surface finishes under 1 micron. Proper control of parameters like voltage, current density, and electrolyte composition are needed to achieve tight tolerances.

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KAMALJEET SINGH
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28 views20 pages

ECG 1st Lecture

Electrochemical grinding (ECG) is a process that combines electrolytic activity with physical material removal using electrically charged abrasive wheels. It produces precise, burr-free cuts without heat or mechanical stresses. ECG removes most material electrolytically, with some removal by the abrasive wheel. It can machine hard materials like tungsten carbide and achieve surface finishes under 1 micron. Proper control of parameters like voltage, current density, and electrolyte composition are needed to achieve tight tolerances.

Uploaded by

KAMALJEET SINGH
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 PPTX, PDF, TXT or read online on Scribd
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ELECTROCHEMICAL

GRINDING
Electrical Energy Based Removing
Techniques

• Electrochemical grinding (ECG)

• Electrochemical Honing

• Electrochemical machining (ECM)

4/21/2017
Electrochemical grinding (ECG)
Working principle
Electrochemical grinding (ECG)
Fig : SCHEMATIC VIEW OF ECG
Electrochemical grinding overview
• Electrochemical grinding is a variation of
ECM that combines electrolytic activity with
the physical removal of material by means of
electrically charged wheels
• ECG can produce burr free and stress free
parts without heat or metallurgical caused by
mechanical grinding , eliminating the need for
secondary machining operations
• Like ECM, (ECG) generates little or no heat that
can distort delicate components
DEFINITION of ECG
Electrochemical grinding is a special from of electrochemical
machining, which employs the combined actions of
electrochemical attack and abrasion to rapidly remove material
from electrically conductive work pieces, usually hard, tough
materials.
 It is a non-abrasive process and, therefore, produce precise
cuts
that are free of heat, stress, burrs and mechanical distortions.
 It is a variation on electrochemical machining that uses a
conductive, rotating abrasive wheel.
ECG can be compared to electroplating, but with major differences,
ECG deplates material from the work and deposits it in the
electrolyte; however, it does not plate material from the work onto the
WHEEL LIFE OF CONVENTINAL AND ELECTRO CHEMICAL
GRINDING
Fig : THREE PHASES OF ECG MATERIAL REMOVAL
PROCESS CHARACTERISTICS
•The wheels and work piece are electrically conductive
•Wheels used last for many grindings - typically 90% of the
metal are removed by electrolysis and 10% from the abrasive
grinding wheel
•Capable of producing smooth edges without the burrs caused
by
mechanical grinding
•Does not produce appreciable heat that would distort work
piece.
•Decomposes the work piece and deposits them into the
electrolyte
solution. The most common electrolytes are sodium chloride
Machining Conditions in ECG
Feed rate 0.25 mm/min
Gap 0.025 mm
Grinding wheel surface speed 25 – 30 m/s
Voltage 5-15 V DC for steel
6 -10 V DC for WC
work material
Current density 50 – 200 A/cm2
Metal removal rate 100 – 500 mm3 /mincm2 on
steel W/P
50 – 200 mm3/mincm2 on
tungsten carbide work
piece
Contact pressure of Varies from 1 to 8 kg/cm2
W/P against the wheel
Electrolyte Water mixed with
NaCl,NaNO3 and NaNO2
Cont…

Accuracy obtainable 0.010 mm


Surface finish 0.1 -0.2 microns
finishes are
possible
Power of motor driving 1 HP
the spindle

Power of motor driving 0.5 HP


the electrolyte
pump

Operating current range 150 – 300 amperes


Rating of power pack 3.5 kVA
Typical surface roughness Data for
Electrochemical metal removal process

Electro – Chemical Surface Roughness Values (RMS)


Metal Removal Range (microns) Average Values
Process

ECM 0.1 -4.0 0.25 – 1.0

ECG 0.1 -1.0 0.10 – 0.5


TOLERANCE
The tolerances that can be achieved using ELECTROCHEMICAL
GRINDING (ECG) depend greatly on the material being cut, the size
and depth of cut and ECG parameters being used.
 On small cuts, tolerances of .0002” (.005mm) can be achieved with
careful control of the grinding parameters.
This kind of grinding is mostly used because it can shape very hard metals
and also because it is a chemical reducing process, the wheel lasts a longer
time than normal grinding wheel can.
This type of grinding has different types of wheels so it can shape metals to
whatever they need to be shaped to.
Produces a smoother, burr-free surface and causes less surface stress than
other grinding methods
Important points to be Observed the
ECG process for Successful
Results
•ECG equipment must be in good condition to achieve best results
in electrolytic grinding
•The carbide work piece should not be allowed to dwell
against the wheel as this will result in pitting
•The diamond wheel must be kept clean in order to maintain the
proper gap between the anode and the cathode. A soft dressing
stick ( aluminum oxide ) may be used for this purpose
•HSS is generally machined with high current density whereas WC
is generally machined with low current density
WHEELS FOR ECG
Diamond wheels. These wheels are used to
electrochemically grind flat surfaces of tungsten carbide tools
and other carbide parts.
Nondiamond-face wheels. This type of wheel is used for
grinding the flat surfaces of steels and alloy steels. The
abrasive used in this type of wheel has been aluminum oxide.
Nondiamond wheels. Dress able resin-bond and copper-
loaded wheels (Copperdyne) are used extensively for all
applications other than tungsten carbide
Diamond Wheel Specification
Shape of Wheel Cup –type Wheel
Bond used Metallic bond (bronze)
Diameter of wheel 250 mm
Width of the rim 20 -25 mm
Diamond D100
concentration used
Mesh no: of diamond 100 to 200
particles used
Wheel speed used 1800 m/min
Grinding ratio 80
FUNCTIONS OF ABRASIVE
WHEEL
During ECG, the abrasive wheel functions as follows:
The abrasive in the wheel continuously removes an electrically resistant
film from the face of the work. If this dielectric film were allowed to remain,
the flow of direct current would stop and there would be no electrochemical
action.
 The abrasive provides an electrically insulated gap between the
cathodic wheel and the anodic work. Without this there would be a direct
electrical short and resultant damage to both the wheel and the work. For
optimum or maximum stock removal, the gap must be less than 0.03
mm.
The wheel carries the electrolyte in the spaces between the abrasive
grains across the face of the work. Without the electrolyte between the
wheel and the work, there would be no electrochemical action.
ELECTROLYTES FOR ECG
Material and its alloys Electrolyte used
Ferrous, Nickel, and Cobalt alloys Sodium chloride

Tungsten carbide Sodium nitrate as the active


ingredient, with rust inhibitor
and chelating-agent additives.

Titanium, Zirconium, and Columbium. Sodium chloride

Tungsten and Molybdenum Sodium carbonate-sodium


hydroxide
Copper or Silver Sodium Nitrite.

Electrolytes are formulated at about 120-240 g/L. Temperature of the electrolyte


is maintained between 30-45 ° C; pressure used to pump the fluid is about 35-70
KPa. Filtration of the electrolyte is important; filtration to 50-100  m is sufficient.

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