ME2026 UNCONVENTIONAL MACHINING PROCESSES

UNIT 4 (2 MARKS)

UNIT-4 CHEMICAL AND ELECTRO CHEMICAL ENERGY BASED PROCESSES

1. State the principle of chemical machining process?
In chemical machining process material is removed from the work piece through a
controlled etching or chemical attack of the work piece material.
2. What is the purpose of etchants in chemical machining?
Etchants are used to remove the material from the work piece. The metal is removed by the
chemical conversion of metal into metallic salt.
3. Name the etchants used in chemical machining processes?

Caustic soda

Hydrochloric acid

Nitric acid

Iron chloride

4. What is the use of maskant in chemical machining?

In chemical machining process, the areas of the work piece which are not to be machined
are covered with a resistant, called a resist or maskant.
5. Write the principles of ECM process?
ECM is based on the principles of faradays laws of electrolysis and reverses
electroplating. In this process, the work piece is connected to positive terminal (anode) and the tool
is connected to negative terminal (cathode). When the current is passed, the work piece loses metal
and the dissolved metal is carried out by circulating an electrolyte between the tool and work.
6. What are the requirements of tool materials in ECM process?

It should be conductor of electricity.

It should be chemically inert to the electrolyte.

It should be easily machinable.

7. What are the factors to be considered while designing the tool?

Determine the tool shape, so that the desired shape of the job is obtained under existing
machining condition

Design the tool by considering the electrolyte flow, insulation strength and fixing
arrangement

8. State the function of electrolyte used in ECM process?

It carries a current between the tool and the work piece

ME2026 UNCONVENTIONAL MACHINING PROCESSES

It cools the cutting zone which becomes hot due to the flow of high current

It removes products of machining from the cutting zone

UNIT 4 (2 MARKS)

9. Name any two electrolyte used in ECM?

20% of Nacl solution in water, mixture of brine and H2SO4, potassium salts and strong
alkaline solution are used as electrolyte in ECM process
10. Name the electrolyte for iron base alloys and ni based alloys?
Iron based alloys20% of Nacl solution in water
Ni based alloys -- mixture of brine and H2SO4
11. Name the electrolyte for ti base alloys & co-cr base alloys?
Ti base alloys10% HF+10% HCL+10%HNO3
Co-Cr base alloysNaCl
13. What are the essential characteristics of an electrolyte used in ECM process?

It should be good conductor of electricity

It should have non corrosive properties

It should have low viscosity and high specific heat

It should have non toxicity and chemical stability

14. What are the materials used for tools in electrochemical machining?
Most commonly used tool materials are copper, brass, titanium, and copper-tungsten and
stain less steel when the electrolyte is made of sodium or potassium
The other materials it can be used as tool materials are aluminum, graphite, bronze,
platinum and tungsten carbide
15. What are the process parameters of electro chemical machining?

Current density

Gap between tool and work piece

Type of electrolyte used

Tool feed rate

16. What are the advantages of ECM?

Metal removal rate is high compared to conventional machining process

Wear and tear of the tool is negligible

The machined work surface is free of stresses

No cutting forces are involved in the process

High surface finish of the order 0.2 to 0.8 microns can be obtained
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ME2026 UNCONVENTIONAL MACHINING PROCESSES

UNIT 4 (2 MARKS)

17. What are the disadvantages of Electro Chemical machining process?

Non-conducting materials cannot be machined

Initial investment is quite high

More space is required

Consumption of power is high

18. List the applications of ECM process.

Machining complicated profiles

Drilling small deep holes

Machining of hard materials and heat resistant materials

Machining of cavities and holes of irregular shapes

19. What are limitations of ECM process?

Sharp internal corners cannot be obtained

Tool design is very complicated and it requires cut and try method to achieve the final
shape

Post machining cleaning is needed to reduce the corrosion of the work piece

20. State the principle of electro chemical grinding process?

In electro chemical grinding method, the work is machined by the combined action of
electro chemical effect and conventional grinding operation. But the major portion of the
metal(about 90%) is removed electrochemical effect.
21. List the advantages of electrochemical grinding(ECG) process?

Tool wear is negligible. So the life grinding wheel is increased.

Good surface finish is obtained.

Burr free and stress free components are [reduced

As compared to conventional grinding, a very little cutting force is applied to the work
piece.

22. List the advantages of ECG process

Initial cost is high

Power consumption is high

Metal remove rate is lower than conventional grinding.

Non-conducting materials cannot be machined.