ELECTROCHEMICAL

MACHINING

SARVESHWARAN J
MATHAN KUMAR K
PARTHIBAN S

ELECTROCHEMICAL MACHINING

ECM process (non conventional machining

process) is the metal removal by controlled
dissolution of anode of an electrolytic cell

This process is particularly suitable for high

strength temperature resistant materials
which are difficult to machine by conventional
machining process

TOOL

In this process the tool acts as a cathode

Tool represents the replica of profile

needed in the workpiece

Copper, brass, titanium, stainless steel

are commonly used tool materials

Electroforming and cold forging are two

methods of tool shaping.

PROPERTIES OF TOOL
MATERIALS

It should be a good conductor of

electricity

It should be rigid enough to take up the

load due to fluid pressure

It should be chemically inert to

electrolyte

It should be easily machinable to make it

to the desired shape

ELECTROLYTE

It carries the current between the tool

and the workpiece

It dissipates heat produced in the

operation

It removes the product of machining

ELECTROLYTE CHARACTERISTICS

Good electrical conductivity

Non toxicity and chemical stability

Non corrosive property

Low viscosity and high specific heat

NaCl, KCl, NaOH, Sulfuric acid, NaF, Sodium

chlorate are commonly used electrolytes

PROCESS

In this process the workpiece acts as an

anode and tool acts as a cathode and they
are connected to the corresponding
terminals of the cell

The electrolyte fills the gap between the

tool and the workpiece thereby completing
the electrical circuit

When power supply is ON, then material

gets removed from the anode(W/p) and
the removed material is carried away by
the electrolyte from machining zone

NEEDS OF TYPICAL ECM

The electric current is of order 50 to

40000 ampere at 5-30V DC for a current
density of 20 to 300A/cm^2
The gap between the tool and the
workpiece is of order 0.05 to 0.7 mm
The electrolyte velocity range is from 30
to 60 m/s
Inlet pressure through which electrolyte is
passed is about 20 kgf/cm^2

METAL REMOVAL RATE

The overall metal removal rates are

governed by Faradays Laws of
Electrolysis

MRR=(EI/F*Density)m^3/s

ADVANTAGES

Surface finish is of order 0.2 to 0.8

microns

Extremely thin metal sheets can be easily

worked without distortion

It can machine configurations which are

beyond the capability of conventional
machining process

LIMITATIONS

The specific power consumption in this

process is nearly 100 times more than in
turning or milling steel.

Nonconducting materials cannot be

machined.

Corrosion and rust of ECM can be a

hazard. But preventive measures can
help in this regard.

WHY ECM?

The metal removal rate by this process is

quite high for high-strength-temperatureresistant(HSTR) materials compared to
conventional machining processes.

Residual stress is low; depth of workhardened layer is known by onehundredth compared to turning
compressive stress is absent.

Tool wear is nearly absent.

APPLICATIONS

Machining of hard-heat-resisting alloys.

cutting cavities in forging dies.
Drilling holes.
Machining of complex external shapes.
Used for machining aerospace
components
Used for machining pharmaceutical
components.

OUR PROJECT
We selected an aerospace component
kown as skylock which is a contrrol lock
used to control push-pull type throttle in
cessna type aircrafts

We also considered an pharmaceutical

application a tablet stamper which is
used to print the design or the trademark
of a particular company on the tablet.

Thank
you