ELECTRO CHEMICAL

MACHINING (ECM)
 BASIC WORKING PRINCIPLES OF ECM

Electrochemical machining is one of the newest and most

useful machining process of metal removal by the
controlled dissolution of the anode of an electrolytic cell.

This process is particularly suited to metals and alloys

which are difficult or impossible to machine by
mechanical machining.
The working principle is based on Michael Faraday’s
classical laws of electrolysis, requiring basically the
two electrodes, an electrolyte, a gap and a source of
D.C. power of sufficient capacity.

ECM is basically the reverse of electroplating

operation.

Almost any conducting material can be machined by

this method.

Non conducting materials cannot be machined.

A schematic sketch of the ECM process is shown next.

 Procedure
In the actual process, the cathode is tool-shaped, more or
less like the mirror image of the finished work piece.

The work piece is connected to the positive supply.

The tool or cathode, connected to the negative terminal,

is advanced towards the anode (work piece) through the
electrolyte that completes the electrical circuit between
the anode and cathode.

Metal is then removed from the work piece through

electrical action and the cathode (tool) shape is
reproduced on the work piece.
The electrolyte bath is pumped at high pressure through
the gap between the work piece and the tool and must be
circulated at a rate sufficiently high to conduct current
between them and carry heat.

The electrolysis process that takes place at the cathode

liberates hydroxyl ions (negatively charged) and free
hydrogen.

The hydroxyl ions combine with the metal ions of the

anode to form insoluble metal hydroxides and the material
is removed from the anode.
This process continues and the cathode (tool) reproduces its shape
in the work piece (anode).

The tool does not contact the work piece producing no direct
friction and therefore does not wear and no heat build up occurs.
Electrolyte
The electrolyte acts as a carrier of current.

The common electrolytes used are sodium chloride,

sodium nitrate, potassium chloride, sodium hydroxide,
sodium fluoride, sulfuric acid, and sodium chlorate.

These solutions on reaction produce an insoluble

compound in the form of sludge.
 Functions of electrolyte
The electrolyte carries the current between the tool and the work
piece.

It removes the machined products and other insoluble products

from the cutting region.

It dissipates the heat produced in the operation.

The electrolyte should posses good electrical conductivity, non-

toxicity, chemical stability, non-corrosive property, low viscosity,
and high specific heat.
Tools
The general requirements on the tool material in
ECM are mentioned below:

The tool material 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 the electrolyte.
It should be easily machinable to make it in the desired
shape.

Copper, Brass, Titanium, Copper-Tungsten, and Stainless

steels are most commonly used electrode materials when
the electrolyte is made of sodium or potassium.

The other materials which can be used as tool materials

are aluminium, graphite, bronze, platinum, and tungsten
carbide.

The cavity or hole that is made, exactly reproduces the

tool shape. Thus the accuracy of the tool shape directly
affects the work piece accuracy.
Parameters
Factors govern the accuracy of parts
produced by ECM:
Machining Voltage ( 2 to 30 V)
Feed rate of the electrode (tool)
Temperature of the electrolyte ( 22 to 45 degree
Celsius)
Concentration of the electrolyte ( g/L H2O)
The table below mentioned the characteristics and applications of
various electrolytes.
 DESIGN CONSIDERATIONS OF ECM
Because of the tendency for the electrolyte to erode away
sharp profiles, electro chemical machining is not suited for
producing sharp square corners or flat bottoms.

Controlling the electrolyte flow may be difficult, so

irregular cavities may not be produced to the desired
shape with acceptable dimensional accuracy.
Designs should make provision for a small taper for
holes and cavities to be machined.

The shaped tool should be either in the form of a

solid or tubular form, and generally made of brass,
copper, bronze, or stainless steel.

The accuracy of the tool shape directly affects the

work piece accuracy.
APPLICATIONS OF ECM
The main applications of ECM process are in machining
of hard-heat-resisting alloys, for cutting cavities in forging
dies, for drilling holes, machining of complex external
shapes like that of turbine blades, aerospace components,
machining of tungsten carbide and that of nozzles in alloy
steels.

Almost any conducting material can be machined by this

method.
It is also used for machining and finishing forging-die cavities (die sinking) and to
produce small holes.

More recent applications of ECM include micromachining for the electronics

industry.
Turbine Blade Electrode
Biomedical Implant Parts made by ECM

(a) (b)
Thank You
1. In ECM, heavy electrical sparks are created.
a) True
b) False

2. In ECM, tool does not touch the work piece.

a) True
b) False

3. Which of the following is correct about ECM?

a) Erosion of metal takes place as reverse process of
electroplating
b) Thermal stresses are induced
c) Mechanical stresses are induced
d) None of the mentioned
4. Which of the following material cannot be machined using
electro chemical machining?
a) Iron
b) Aluminum
c) Copper
d) Wood

5. Electrode gap in electro chemical machining is generally

ranges from
a) 0.5 mm to 0.9 mm
b) 1.1 mm to 1.2 mm
c) 0.1 mm to 0.2 mm
d) 3.1 mm to 4.2 mm
6. Electrolytes used in ECM must posses
a) Low electrical conductivity
b) Low chemical stability
c) High electrical conductivity
d) None of the mentioned

7. Which of the following is not a function of electrolyte in

ECM?
a) It completes the circuit
b) It helps in electrochemical reaction
c) It carries away heat and waste product
d) It provide non reactive environment
8. How does the current pass between the two electrodes in ECM?
a) Electrolytic solution
b) Direct contact of electrodes
c) All of the mentioned
d) None of the mentioned

9. What is the value of velocity with which, electrolyte flows in the inter electrode
gap?
a) >1 m/s
b) >3 m/s
c) >5 m/s
d) >10 m/s

10. Of the following, electrolyte removes which of the dissolution products?

a) Metal hydroxides
b) Heat
c) Gas bubbles
d) All of the mentioned