Chapter 6

Electrochemical Spark Machining

Dr. J. Ramkumar1 and Vyom Sharma2

1Professor and 2Research Student

Department of Mechanical Engineering

Micromanufacturing Lab, I.I.T. Kanpur
Micromanufacturing Lab, I.I.T. Kanpur
 Chapter 6

Electrochemical Spark Machining

Dr. J. Ramkumar
Professor, Department of Mechanical Engineering
Micro machining Lab, I.I.T. Kanpur

Micromanufacturing Lab, I.I.T. Kanpur

 Organization of the presentation

1. Overview of Electrochemical Spark Machining Process

(Introduction to Machining Process, Mechanism of spark formation and material removal)

2. Process and performance parameters of ECSM

3. Machining system of ECSM process

4. Variants of ECSM process

5. Hybridized ECSM processes

6. Future scopes of research

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1. Overview of Electrochemical spark machining (ECSM) process

ECSM process is a novel combined/hybrid machining method developed to

machine electrically nonconductive materials. Generally, it comprises thermal
energy based on two unconventional machining processes, that is, ECM and EDM.

Due to the combined effect of EDM and ECM, the ECSM process successfully
overcomes the drawbacks of the constituting processes (EDM and ECM) as
requirement of the electrically conductive materials for machining. The process
capabilities are not only limited to nonconductive materials and also applied for
shaping of electrically conductive materials.

Generally, process capability in terms of material removal of ECSM process is much

higher (approx. 5 and 50 times) as compared to ECM and EDM, respectively, at
same machining conditions.

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1. Overview of Electrochemical spark machining (ECSM) process
Comparison between ECM, EDM, and ECSM

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1. Overview of Electrochemical spark machining (ECSM) process
Spark formation phenomenon in ECSM

In ECSM process, the combined effects of

constituent processes (ECM and EDM) are
responsible for material removal. Generally,
hydrogen (H2) gas bubbles are generated due to
electrolysis process or electro-chemical reaction
while electrical discharge/spark is produced between
gaseous layer formed by gas bubbles and tool
electrode (cathode) in the presence of electrolyte.
Therefore, two phenomena, that is, hydrogen (H2) gas
formation and spark generation, cause material
removal in ECSM. The material is removed due to
simultaneous effect of melting, vaporization and
chemical etching processes.

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1. Overview of Electrochemical spark machining (ECSM) process
Spark formation phenomenon in ECSM

The temperature of plasma channel is in the range of 800–20,000K. At this temperature, any non-
conductive material is placed near the sparking zone with appropriate inter electrode gap (IEG) and then
material removal takes place from workpiece surface due to melting and vaporization. Such phenomenon
is known as material removal mechanism of ECSM process. Generally, IEG between tool-electrode and
workpiece is in few micro-meters and depends on the machining conditions. The IEG between tool
electrode and workpiece is 20mm or less than 25mm for machining of glass.
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1. Overview of Electrochemical spark machining (ECSM) process
Equivalent circuit for ECSM process

No sparking

At critical accumulation condition

Circuit used for calculation of

At the time of sparking spark energy
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2. Process and Performance parameters of (ECSM) process

Process
Parameters

Electric Non-electric
Parameters Parameters
Polarity Electrolyte

Current Pulse Frequency

density duration
Discharge Pulse Tool
interval Flushing
voltage electrode

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 2. Process and Performance parameters of (ECSM) process

Performance
Parameters

Material Surface
removal rate roughness
Tool wear
rate

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 3. Machining system of Electrochemical Spark Machining Process
Following are the constituents of a typical machining system used in a ECSM process:

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 3. Machining system of Electrochemical Spark Machining Process
Experimental setup of Electrochemical Spark Machining process:

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 4. Variants of Electrochemical Spark Machining Process
Drilling ECSM: It can be used in different configurations such as through-hole
drilling, blind hole drilling, counter drilling and percussion drilling. In drilling,
flushing capability is highly affected by peripheral velocity of drilling tool
resulting in enhancement in machinability with higher material removal with
better surface quality. Instead of this, the rotational speed of the tool leads to a
reduction in stray corrosion resulting in improvement in the circularity of drilled
hole. Generally, low rotational speed is better for higher material removal with
good surface finish and vice versa at higher speed.

Sinking ECSM: Sinking ECSM process can be used to create micro holes in the
workpiece with application of stationary tool-electrode (reciprocating type) for
manufacturing of moulds and dies. Generally, sinking ECSM process has been
used for making of through- and blind micro holes in the workpiece to achieve
higher aspect ratio. It also shows their potential to make small and shallow (ultra-
precision) features for nozzles, orifices, dies and moulds made of non-conductive,
semi-conductive or conductive materials.

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 4. Variants of Electrochemical Spark Machining Process
Turning ECSM: The feeding mechanism for workpiece during turning ECSM is
not required resulting in reduction in the complexity. This process becomes
beneficial for turning of different profilers such as cylindrical turning, taper
turning, step turning and thread turning operations.

Milling ECSM: Milling ECSM process shows their potential to create three-
dimensional (3D) micro structures, cavities and profiles on the surface of non-
conductive materials by adopting the strategy of tool-electrode movement similar
to conventional milling.

Travelling Wire ECSM: In TW ECSM, the spark is generated between moving

wire made of copper, brass or tungsten and at the surface of workpiece as a result
of melting, vaporization and erosion of workpiece material. It is widely applicable
for shaping of complex profile in non-conductive materials with application of
movable wire (tool-electrode) on any surfaces (internal or external) for micro-
cutting such as gear cutting, comb profiles, chutes or channels.
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 4. Variants of Electrochemical Spark Machining Process

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 5. Hybridizations of Electrochemical Spark Machining Process

To enhance the performances of ECSM process and to minimize/eliminate the

drawbacks, the researchers combined or hybridized ECSM process with other
machining processes. Such combined processes are called as hybridized ECSM or
ECSM-based hybrid machining processes.
The purposes of the hybridization of ECSM with different machining processes are
to utilize the potential merits and at the same time dismiss the demerits of the
constituent processes as a result enhancement in the machinability of the hybridized
ECSM processes.
Hybridized ECSM processes are classified based on (a) Energies or (b) Involvement
of constituent processes in machining.
On the basis of energy sources, the mechanical or magnetic force is used for
hybridization of ECSM process.
Based on involvements, the hybridized ECSM can be classified as associated and
assisted type hybridized ECSM.

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 5. Hybridizations of Electrochemical Spark Machining Process
Hybridization of ECSM based on energy source:

Mechanical Energy based Magnetic Energy based

hybrid ECSM process hybrid ECSM process

Ultrasonic assisted sinking ECSM Magnetic force assisted ECSM

Ultrasonic assisted drilling ECSM Magnetic force assisted abrasive

grinding ECSM
Electrochemical spark abrasive
grinding (ECSAG) Ultrasonic magnetic force assisted
abrasive grinding ECSM
Ultrasonic assisted ECSAG
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 5. Hybridizations of Electrochemical Spark Machining Process
Hybridization of ECSM based on involvement:

Associated type hybrid Assisted type hybrid

ECSM process ECSM process

All the constituent processes The constituent processes are not

directly involve to improve the directly involved in improving the
machinability and continuously machinability, and among them
make their efforts toward that only one process is directly
direction. involved in machining, while
Ex: ECSAG other processes facilitate or assist
UA-ECSAG the machining method.
MA-ECSAG Ex: UAS ECSM
PM-ECSAG (Powder mixed) UAD ECSM
MA ECSM

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 5. Hybridizations of Electrochemical Spark Machining Process

Classification of Hybridized ECSM process:

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 5. Hybridizations of Electrochemical Spark Machining Process

Electrochemical Spark Abrasive Grinding Process (ECSAG):

In this process, the material removal occurs due to chemical dissolution, spark
erosion and abrasive abrasion, that is, three different energies such as chemical,
thermal and mechanical are responsible for material removal.
To implement the abrasion action of grinding ECSM process, a metallic wheel with
abrasive (metal bonded) aided has been applied during machining and the process
becomes as ECSAG.
Spark phenomenon occurs between bond material (metallic part) and gas bubbles
due to which the workpiece material melted and vaporized.
Simultaneously, abrasive particles make contact with workpiece surface and soften
material removed due to abrasion action of abrasive particles.

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 5. Hybridizations of Electrochemical Spark Machining Process

Electrochemical Spark Abrasive Grinding Process (ECSAG)

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 5. Hybridizations of Electrochemical Spark Machining Process

Powder Mixed Electrochemical Spark Machining Process (PM ECSM):

In PM ECSM, loose conductive particles are mixed with electrolyte to improve the
surface integrity of ECSM process.

Generally, the generation of fine spark with uniform energy and their fine control
are highly desired to get higher machinability and surface finish.

Due to the presence of loose abrasive particles in electrolyte, a lot of particles make
contact with workpiece surface freely resulting in small amount of material being
removed from workpiece surface. This phenomenon leads to improve the SQ and
help to achieve the SQ up to micro/nano level.

The abrasion action of abrasive particles also minimized/removed the micro-cracks

on the machined surface.

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 5. Hybridizations of Electrochemical Spark Machining Process

Electrochemical Spark Abrasive Drilling Process (ECSAD):

Electro-chemical spark abrasive drilling (ECSAD) is the implementation of
abrasive-based tool-electrode in drilling ECSM process.

In this process, three different energies such as chemical, electrical and mechanical
are used to perform chemical dissolution, spark erosion and abrasive abrasion
phenomena.

Abrasive particles make sufficient gap between the workpiece and bond materials
due to effective protrusion heights, and as a result huge amount of bubble are
formed during chemical reaction.

Material removal decreases with an increase in depth, and after a certain depth, the
machining becomes much difficult. This is due to lack/insufficient formation of gas
bubbles at higher depth.
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 5. Hybridizations of Electrochemical Spark Machining Process

Ultrasonic assisted Electrochemical Spark Drilling Process (UA ECSD):

Ultrasonic assisted electro-chemical spark drilling (UA ECSD) is an application of
mechanical energy in the form of vibration (ultrasonic) in drilling ECSM process.
Ultrasonic vibration in ECSM effectively changes the discharge behaviour and
improves the electrolyte circulation, as a result no accumulation of debris takes
place as which stable sparks are generated.
The purposes of ultrasonic vibration in drilling ECSM are to enhance machining
performances such as material removal and surface quality of the drilled workpieces
by improving the circulation of electrolyte into the gap between tool-electrode and
workpiece during machining.
Vibration speeds up the machining discharge and also controls the hydrodynamic
machining process resulting in higher material removal.
Vibrational amplitude of 10mm creates the most uniform current signal in
machining zone resulting in uniform and stable sparks.

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 5. Hybridizations of Electrochemical Spark Machining Process

Ultrasonic assisted Electrochemical Spark Abrasive Grinding Process (UA

ECSAG):
UA ECSAG is the application of ultrasonic vibration in ECSAG process.
It is observed that after each spark, white oxide layer forms on the surface of
grinding wheel, thus decreasing the protrusion heights of abrasive particles and
reducing the material removal rate.
The thickness of oxide layer formation is inversely proportional to ultrasonic
vibration (amplitude and frequency). Therefore, the application of ultrasonic
vibration in ECSAG is an effective way of in-process dressing method of diamond
grinding wheel.

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 5. Hybridizations of Electrochemical Spark Machining Process

Magnetic field assisted milling ECSM process (MAM ECSM):

In this process, magnetic force is applied with milling ECSM process with an
application of a permanent magnet.
The basic advantage of magnetic field in ECSM process is the development of
magneto hydro-dynamic (MHD) convection into the gap between the workpiece and
tool-electrode in the presence of electrolyte.
Due to this, there is effective circulation of electrolyte which facilitates deep hole
machining and finally generates better geometry of machined surfaces.
Magnetic force assists to generate more stable spark and easily breaks of the gas
bubbles away from the surface of tool-electrode. As a result, a uniform layer of
gaseous zone has been formed surrounding the surface of the tool-electrode which
contributes to higher machining rate due to requirement of higher supply voltage in
the machining zone.

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 5. Hybridizations of Electrochemical Spark Machining Process
Magnetic field assisted Travelling wire ECSM process (MA TW-ECSM):
In TW ECSM process, the circulation of electrolyte into the gap defers in the close
vicinity of the machining zone resulting in decline in material removal.

To overcome the above problem, the application of MHD convection in TW ECSM

process becomes beneficial.

The MHD convection pushes the electrolyte into the sparking zone (gap between
tool-electrode and workpiece), and finally a uniform gaseous environment is
obtained surrounding the tool-electrode.

Such a phenomenon leads to uniform presence of hydrogen gases resulting in

uniform and precise formation of sparks.

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 5. Hybridizations of Electrochemical Spark Machining Process
Summary of Hybridized Electrochemical Spark Machining Processes:

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 6. Future scopes of research
After sophisticated studies, it is concluded that only limited hybridized ECSM
processes are developed till now and several other new hybridized ECSM processes
can be developed to improve the capabilities of existing processes.

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 6. Future scopes of research
Proposed hybridized ECSM processes to be developed are as follows:
Ultrasonic Vibration Powder Mixture Magnetic force Magnetic force and
based based based ultrasonic vibration
based

Ultrasonic assisted sinking Powder mixed sinking Magnetic force assisted sinking Magnetic force and ultrasonic
ECSM ECSM ECSM assisted sinking ECSM
Ultrasonic assisted milling Powder mixed drilling Magnetic force assisted drilling
ECSM ECSM ECSM Magnetic force and ultrasonic
Powder mixed milling Magnetic force assisted turning assisted milling ECSM
Ultrasonic assisted turning
ECSM ECSM ECSM
Magnetic force and ultrasonic
Ultrasonic assisted TW Powder mixed turning Magnetic force aided grinding assisted turning ECSM
ECSM ECSM ECSM
Ultrasonic assisted saw-cut Powder mixed saw-cut Magnetic force aided Magnetic force and ultrasonic
ECSM ECSM ECSAG assisted grinding ECSM
Ultrasonic assisted grinding Powder mixed
ECSM ECSAG

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 Conclusions
1. ECSM is a hybrid machining process that comprises the features of EDM and
ECM processes for shaping of electrically conductive and nonconductive
materials at micro-level machining.
2. ECSM process developed in different configurations such as drilling ECSM, TW
ECSM, milling ECSM, sinking ECSM, grinding ECSM and turning ECSM
positively create complex profiles with better surface quality during machining.
3. Hybridization with ECSM process is a novel trend to enhance the productivity
of ECSM process. Grinding ECSM becomes an appropriate method to develop
micro-tools for micro-machining related to EDM, ECM or ECSM process.
4. Saw-cut ECSM is a new configuration of ECSM and is a good approach for
slice/disk cutting of difficult-to-cut non-conductive materials.
5. Ultrasonic vibration–assisted ECSM enhances the flow of electrolyte into the
gap resulting in reduction in arcing phenomenon. Such an approach effectively
improves material removal, surface quality and reduces micro-cracks.

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 Conclusions
6. Abrasive-aided grinding ECSM shows their potential to remove micro-cracks and
recast layer formed due to spark energy at the workpiece surface. It significantly
enhances material removal and surface quality. It is a unique technique for dressing
of micro-tools/wheels.

7. Several more hybridization of ECSM process can be possible to get better

performances of the existing ECSM process. This becomes advantageous for
researchers to develop new process/method in the field of ECSM to machine the
difficult-to-machine materials.

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 Thank You

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