Assignment

on

Electrochemical grinding machining

University institute of engineering and technology

Kurukshetra

Submitted to Submitted by

MR. Ravinder chaudhary Lovepreet singh

Course -MTIP-601 Roll no.251756007

NCM

Date:11/11/2017
 Electrochemical Grinding (ECG)

Introduction

ECG is also known as electrolyte grinding, anodic machining or electrolytically assisted abrasive grinding
it involve the use of a metallic grinding wheel and the process can be used for all the standard grinding
operation viz, surface grinding, internal grinding and face grinding, etc. the specific use of this machine
process is in grinding such material which cannot be otherwise easily Shared due to either their extreme
hardness or too high tensile strength some of such material or cemented carbide, hardened Steel,
stainless steel and some Steel alloys.

On the Periphery of the grinding wheel are attached the abrasive particles which act as insulators,
preventing a direct contact between the wheel and the workpiece. The electric current between two
flows through the electrolyte and the metal removal from the workpiece is through electrolyte action.
The abrasive particles on the surface of the wheel remove the decompresed material to provide a fine
surface finish the adequate dimensional control. As a result of this process carried out in the above
explained manner, there are no chances of the production of thermal stresses or cracks etc. The rate of
stock removal is sufficiently high and surface finish of high quality.

A typical setup of ECG is shown in the figure.

Set-up for ECG Process

The grinding wheel is mounted on a spindle, which rotate inside suitable bearings. the workpiece is held
on the machine table is
suitable fixtures. The table
can be moved forward and
backward to feed the work
or to withdraw it. The
grinding wheel and spindle
are insulated from the rest
of the machine by using an insulating sleeve, as shown. Electrolyte from the tank is pumped into the gap
between the wheel.

Working principal

The process consists of connecting the grinding wheel to negative terminal and workpiece to the positive
terminal to make the formal a 'cathode' and the letter 'anode' .The power supply unit is D.c. and provide
an automatic voltage adjustment between 2 to 30 V. The coolant used in this process is an electro-
conductive electrolyte, such as aqueous solution of water glass.The grinding wheels run at a surface
speed of about 1500 metres per minute.

Element of ECG Process

The Elements of ECG Process are as follows:

1. Cathode (tool).

2. Anode (workpiece).

3. D.c. power sources.

4. Electrolyte.

1. Cathode (tool).

Cathode polarity
with respect to the anode
can be positive or
negative; it depends
on how the device
operates. Although
positively charged cations always move towards the cathode (hence their name) and negatively charged
anions move away from it, cathode polarity depends on the device type, and can even vary according to
the operating mode. In a device which takes energy (such as recharging a battery), the cathode is
negative, and in a device which provides energy (such as discharging a battery), the cathode is positive:

2. Anode (Workpiece).
The workpiece used should be good conductor of electricity because chemical property of the workpiece
offset the material removal rate is directly proportionalto the atomic weight and inversely proportional
to the velocity of workpiece thus workpiece with high atomic weight are preferably for ECM.

3. D.c. power supply

For the ECM process, The power supply unit is D.c. and provide an automatic voltage adjustment
between 5 to 15 V. voltage of low intensity is required. In this process A.c supply is converted into low
D.c voltage by step down transformer and rectifier

4. Functions of Electrolyte

The current is carried between the tool and the w/p through electrolyte.
The produced heat is dissipated by the liquid electrolytic solution.
The product of machining is removed by the solution.
It keeps the reactions continuous by supplying the elements necessary for the reaction.

Process characteristics

The wheels and workpiece are electrically conductive.

Wheels used last for many grindings - typically 90% of the metal is 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 workpiece.
Decomposes the workpiece and deposits them into the electrolyte solution. The most common
electrolytes are sodium chloride and sodium nitrate at concentrations of 2 lbs.

Material Removal

Most of the material removal in electrolytic grinding is by electrochemical action. Some of the metal is
mechanically removed by the abrasive which is in contact with the work. The main function of the
abrasive particles are:

1. To provide insulation between the anode and cathode and to determine the effective gap thickness
between them

2. To continually remove any passive layer that may be formed on the work piece.

In general particles metal removal rate with ECG are of the order of 1.0 cm3/min/100A. However, 0.5
cm3/min/100A is often used for approximation.

Advantage of Elctrochemical Grinding (ECG).

 Improved wheel life
Increase MRR
Burr free
No work hardening
Stress free
Better finish
No cracking
Less frequent wheel dressing
No metallurgical damage from heat
Faster for tough materials
No wheel loading or glazing
More precise tolerances

Disadvantage of Electrochemical grinding

This process can be used to machine only metals which are conductive.
Sharp corners of the work piece cannot be machined.
Electrolytic solution is corrosive.
Initial cost of the equipment is high.
Intricate shapes may not be formed.
High power consumption.

Applications of ECG

Grinding turbine blades.

Sharpening of carbide tips and tools.
Cutting thin sections of hard materials without danger of any damage or distortion.
Granding honeycomb metals for Aerospace application.
ECG is used to remove surface defect from parts where excessive material removal and residual
stresses are undesired such as re-profiting locomotive gears.