ELECTRO CHEMICAL MACHINING (ECM)

Principle-
The machining process is based on the principle known as electrolysis, in
which the electrical energy is used to produce a chemical reaction,
therefore the machining process is called electrochemical machining. This
process works on the principle of Faradays Law of electrolysis.
The weight of the substance produced during electrolysis is directly
proportional to:
1. Equivalent weight of the material
2. Current which passes
3. Length of the time process

ECM Metal Removal Rate is independent of hardness of work.

Where, F = faradays constant = 96,500 Columns = 26.8 amp-hours,

I = current flowing in amperes,
Z = Valances of metal dissolved,
A = atomic weight of material in grams,
MRR = Material removal rate in grams per second.
Working Equipment-

ECM machines come in both vertical and horizontal types. Depending on

the work requirements, these machines are built in many different sizes as
well. The vertical machine consists of a base, column, table, and spindle
head. The spindle head has a servo-mechanism that automatically
advances the tool and controls the gap between the cathode (tool) and
the work piece.

Process parameters-

Power Supply
Type direct current
Voltage 2 to 35 V
Current 50 to 40,000 A
Current density 0.1 A/mm2 to 5 A/mm2
Electrolyte
Material NaCl and NaNO3
Temperature 20oC 50oC
Flow rate 20 lpm per 100 A current
Pressure 0.5 to 20 bar
Dilution 100 g/l to 500 g/l
Working gap 0.1 mm to 2 mm
Overcut 0.2 mm to 3 mm
Feed rate 0.5 mm/min to 15 mm/min
Electrode material Copper , brass, bronze
Surface roughness, Ra 0.2 to 1.5 m

Merits-

Complex, concave curvature components can be produced

easily by using convex and concave tools.
Tool wear is zero, same tool can be used for producing infinite
number of components.
No direct contact between tool and work material so there are
no forces, residual stresses.
The surface finish produced is excellent.

Demerits-
Out of all the unconventional machining methods, electro
chemical machining requires high specific cutting energy.
 Sharp edges and corners are not possible to produce.
Work material must be electrically conducting.
Generally preferable for producing contours only.

Applications-

Electro chemical machining technique removes material by atomic level

dissolution of the same by electro chemical action. Thus the material
removal rate (MRR) is independent on the mechanical or physical
properties of the work material. ECM can machine any electrically
conductive work material irrespective of their hardness, strength or even
thermal properties. Moreover as ECM leads to atomic level dissolution, the
surface finish is excellent with almost stress free machined surface and
without any thermal damage. Mainly ECM is used for producing complex
shapes of compound like turbine blades.

ECM is used commonly for operations like

Die sinking
Profiling and contouring
Trepanning
Grinding
Drilling
Micro-machining