Electrochemical Machining(ECM)

• Identify ECM as a particular type of Non-

traditional process
• Basic working principle of ECM
• Schematic of ECM setup
• Mechanism of material removal
• Process parameters in ECM
• Applications of ECM and schematic of
application areas
 Basic working principle of ECM
• ECM is based on the principle of Faraday’s law of
electrolysis.
• If two electrodes are immersed in a conducting
liquid and a D.C. potential is applied across them,
then metal is depleted from the tool (anode) and
plated on the workpiece (cathode).
• This process is widely used in electroplating by
making w/p as the cathode.
• But, in ECM, electroplating is reversed.
• The material has to be removed from the w/p
and hence w/p is made the anode.
Contd…
• In ECM, w/p and tool are immersed in a solution
which is an electrolyte.
• NaCl salt is generally used to prepare aqueous
solution for the electrolyte.
• ECM is opposite of electro-chemical deposition
or electroplating.
• ECM is a controlled anodic dissolution process.
• The w/p is connected to positive terminal and
tool is connected to negative terminal.
• The w/p is made anode and tool is made
cathode.
 Contd…
• The voltage applied is very low. But, the amount
of current which passes through the electro-
chemical cell is rather high.
Contd…
• During initial stage of ECM, the machining gap is
rather high.
• But, during steady state operation, the tool has
to be fed continuously so that a specific
machining gap is to be maintained. (Refer Fig. 1)
ECM process
 ECM process (Refer Fig. 2)
• Consider an example of
machining of low carbon steel
which is a ferrous alloy mainly
containing iron.
• A neutral salt solution of NaCl is
taken as the electrolyte. The
electrolyte and water undergo
ionic dissociation forming Na+
ions and Cl- ions as well as H+
and OH- as potential difference
is applied.
• Also, ferrous ions will come out
of the w/p (anode) and react
with chlorine ions and hydroxyl
ions to form FeCl2 and Fe(OH)2 .
Contd…
• The hydrogen ions are positive. These ions will
move towards the tool (cathode) which is
connected to the negative terminal and
hydrogen gas will evolve at cathode.
• Thus, controlled anodic dissolution will have
machining on the w/p (anode).
• As the material removal takes place due to
atomic level dissolution, the machined surface
is of excellent surface finish and stress free.
 Process Parameters of ECM
• Type – D. C. supply
• Voltage – 2 to 35 V
• Current – 50 A to 40000 A
• Current density – 0.1 A/mm2 to 5 A/mm2
• Working gap – 0.1 mm to 2 mm
• Overcut – 0.2 mm to 3 mm
• Feed rate – 0.5 to 15 mm/min
• Electrode material – Copper, brass, bronze
• Ra value – 0.2 to 1.5 μm
Schematic of ECM setup
 ECM-Equipment (Refer Fig. 4)
• The electrolyte passes through a pressure relief
valve, flow meter and pressure gauge and then it
enters the hollow tool (cathode).
• The outer surface of the tool is provided with an
insulation to reduce overcut.
• The electrolyte moves over the working surface.
• When a D.C. voltage is applied, gradually there is
an electrochemical dissolution on the w/p
surface.
• To maintain a machining gap, a servomechanism
is required for continuously feeding the tool.
 Contd…
• W/p gets gradually machined and precipitate as
the sludge of FeCl and Fe(OH)2 . These sludges
are to be removed from the working tank.
• So, these sludges are taken out by a valve and
then made to pass through a centrifuge or
separation unit.
• The sludges are separated in separation unit
and the electrolyte is fed back again into the
electrolytic tank.
 Characteristics of ECM
• Tool and w/p material is electrically conductive.
• Atomic level dissolution
• Excellent surface finish
• Stress free machined surface
• No thermal damage
 Applications of ECM
• Die sinking – Dies of complex geometry can be
made
• Profiling – A complex w/p can be machined
 Applications of ECM
• Drilling and Trepanning – Very large holes can be
trepanned.